CN105592997A - Polymeric material for an insulated container - Google Patents

Abstract

A formulation includes a polymeric material, a nucleating agent, and a blowing agent. The formulation can be used to form a container.

Description

Polymer materials for insulating containers

priority claim

This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application Serial No. 61/866,741, filed August 16, 2013, and U.S. Provisional Application Serial No. 61/949,126, filed March 6, 2014, which Both US provisional applications are expressly incorporated herein by reference.

background

The present disclosure relates to polymeric materials capable of being shaped to create containers, and in particular insulating polymeric materials. More specifically, the present disclosure relates to polymer-based formulations that can be shaped to produce insulating non-aromatic polymeric materials.

overview

A polymeric material according to the present disclosure includes a polymeric resin and a cell former. In an exemplary embodiment, the blend of polymeric resin and cell former is extruded or otherwise formed to produce an insulating cellular non-aromatic polymeric material.

In an exemplary embodiment, an insulative cellular non-aromatic polymer material produced according to the present disclosure may be shaped to produce an insulative cup or other product. In an illustrative embodiment, polypropylene resin is used to form the insulative cellular non-aromatic polymer material.

In an exemplary embodiment, the insulative cellular non-aromatic polymer material comprises a polypropylene base resin having a high melt strength, a polypropylene copolymer or homopolymer (or both), and at least one component Cell formers for nucleating and blowing agents such as carbon dioxide. In an illustrative embodiment, the insulative cellular non-aromatic polymer material further includes a slip agent. The polypropylene base resin has a broad unimodal (non-bimodal) molecular weight distribution.

In an illustrative example, a polypropylene-based formulation according to the present disclosure is heated and extruded in two stages to produce a tubular extrudate (in the extrusion process), which can be The material is cut to provide strips of insulative cellular non-aromatic polymeric material. In an exemplary embodiment, a blowing agent in the form of an inert gas is introduced into the molten resin during said first extrusion stage.

In an illustrative embodiment, an insulative cup is formed using a strip of the insulative cellular non-aromatic polymer material. The insulated cup includes a body including a sleeve-like side wall, and a bottom coupled to the body to cooperate with the side wall to form a cup for storing food, liquid, or any suitable product internal area. The body also includes a bead coupled to the upper end of the side wall and a bottom bracket coupled to the lower end of the side wall and the bottom.

In an exemplary embodiment, the insulative cellular non-aromatic polymeric material is configured to provide an insulative cell for use in at least one selected region of the body (e.g., sidewalls, beads, bottom bracket, and including means for localized plastic deformation within said bottom bracket (flange securing the base) to provide (1) a plastically deformed first material section at a selected portion of said body having a first density in a first portion of the region, and (2) a second material segment having a relatively lower second density in an adjacent second portion of the selected region of the body. density. In an illustrative embodiment, the first material section is thinner than the second material section.

Additional features of the disclosure will become apparent to those skilled in the art upon consideration of the illustrative embodiment which illustrates what is presently considered the best mode of carrying out the disclosure.

Brief description of the drawings

The detailed description relates in particular to the accompanying drawings, in which:

FIG. 1 is a diagrammatic perspective view of a method of forming a material according to the present disclosure showing the method of forming a material comprising, from left to right, placing a formulation of an insulative cellular non-aromatic polymeric material into Hopper, which feeds into the first extrusion zone of the first extruder (where heat and pressure are applied to form the molten resin) and shows injecting blowing agent into the molten resin to form the extruded a resin mixture, the extruded resin mixture is fed into a second extrusion zone of a second extruder, where the extruded resin mixture is expelled and expanded to form an extrudate, the extrudate is cut to form strips of insulative cellular non-aromatic polymeric material;

2 is a perspective view of an insulative cup made from a strip of material comprising the insulative cellular non-aromatic polymer material of FIG. 1, showing the insulative cup comprising a body and bottom, and showing that four regions of the body have been sectioned to reveal regions of localized plastic deformation providing increased density in those regions while maintaining predetermined insulating properties within the body;

3 is an enlarged cross-sectional view of a portion of a side wall included in the body of the insulative cup of FIG. the skin layer, the ink layer, and the adhesive layer, and the strip of insulative cellular non-aromatic polymeric material of FIG. 1;

4 is an exploded assembly view of the insulative cup of FIG. 2, the figure showing that the insulative cup includes, from top to bottom, a bottom and a main body that includes a bead, side walls, and is configured to make the bottom a bottom bracket interconnected with said side walls, as shown in Figure 2;

5 is a cross-sectional view taken along line 5-5 of FIG. 2 showing that the side walls included in the body of the insulative cup include a generally uniform thickness and that the bottom and the side walls included in the said bottom bracket in said body;

6-9 are a series of views showing first, second, third, and fourth regions of the insulative cup of FIG. 2, each of said regions including localized plastic deformation;

FIG. 6 is a partial cross-sectional view taken along line 5-5 of FIG. 2 showing that the first region is within the sidewall of the body;

FIG. 7 is a partial cross-sectional view taken along line 5-5 of FIG. 2 showing that the second region is within the bead of the body;

FIG. 8 is a partial cross-sectional view taken along line 5-5 of FIG. 2 showing the third region within a connecting web included in the bottom bracket of the main body;

FIG. 9 is a partial cross-sectional view taken along line 5-5 of FIG. 2 showing the fourth region within a web support ring included in the bottom bracket of the main body;

10 is a graph illustrating the performance over time of an exemplary embodiment of an insulative cup according to the present disclosure when subjected to a temperature test;

11 is a graph showing thermal temperature performance over time of an insulated cup according to the present disclosure when subjected to a temperature test as described in Example 3 Insulation Thermal Test Method;

12 is a graph showing thermal temperature performance over time of an insulative cup according to the present disclosure when subjected to a temperature test as described in Example 3 Insulation Thermal Test Method;

13 is a graph showing the cold temperature performance over time of an insulated cup according to the present disclosure when subjected to a temperature test as described in Example 3 Insulation Cold Test Method;

14 is a graph showing the cold temperature performance over time of an insulated cup according to the present disclosure when subjected to a temperature test as described in Example 3 Insulation Cold Test Method;

Figure 15 is a photograph of a tray made of the insulative cellular non-aromatic polymeric material;

FIG. 16 is a graph showing outer side wall temperature over time for cups tested in Example 6;

Figure 17 is a graph showing the outside wall temperature of the cups tested in Example 7 over time;

Figure 18 is a graph showing the outer side wall temperature over time for cups tested in Example 8;

Figure 19 is a graph showing the outer side wall temperature over time for the cups tested in Example 9; and

FIG. 20 is a graph showing outer side wall temperature over time for cups tested in Example 10. FIG.

Detailed description

The insulative cellular non-aromatic polymeric material produced in accordance with the present disclosure can be shaped to produce an insulative cup 10 as shown in Figures 2-9. As an example, the insulative cellular non-aromatic polymeric material comprises a polypropylene base resin having a high melt strength, a polypropylene copolymer or homopolymer (or both), and at least one nucleating agent Cell formers with blowing agents such as carbon dioxide. As a further example, the insulative cellular non-aromatic polymer material further includes a slip agent. The polypropylene base resin has a broad unimodal (non-bimodal) molecular weight distribution.

Material formation process 100 uses polypropylene-based formulation 121 according to the present disclosure to produce strip 82 of insulative cellular non-aromatic polymer material, as shown in FIG. 1 . The formulation 121 is heated and extruded in two stages to produce a tubular extrudate 124 which can be slit to provide strips 82 of insulative cellular non-aromatic polymeric material, for example as shown in FIG. shown in 1. A blowing agent in the form of a liquefied inert gas is introduced into the molten resin 122 in the first extrusion zone.

An insulative cellular non-aromatic polymer material is used to form the insulative cup 10 . The insulating cup 10 includes a main body 11 having sleeve-like side walls 18 and a bottom 20 as shown in FIGS. 2 and 4 . Bottom 20 is coupled to body 11 and cooperates with side walls 18 to form interior region 14 therebetween for storing food, liquid, or any suitable product. The body 11 also includes a bead 16 coupled to the upper end of the side wall 18 and a bottom bracket 17 interconnecting the lower end of the side wall 18 and the bottom 20 , as shown in FIG. 5 .

The insulative cellular non-aromatic polymer material is configured in accordance with the present disclosure so as to provide for use in at least one selected region of the body 11 (e.g., the sidewall 18, the bead 16, the bottom bracket 17, and the bottom bracket included in the bottom bracket). means for achieving localized plastic deformation in the flange 26) of the fixed bottom in 17, so as to provide (1) a plastically deformed first material section in a first portion of a selected area of the main body 11 having a first density in the body 11, and (2) a second material segment having a relatively lower second density in a second portion adjacent to the selected region of the body 11, such as in shown in Figures 2 and 6-9. In an illustrative embodiment, the first material section is thinner than the second material section.

One aspect of the present disclosure provides formulations for making insulative cellular non-aromatic polymeric materials. As referred to herein, an insulative cellular non-aromatic polymeric material refers to an extruded structure having cells formed therein and having the desired insulating properties at a given thickness. Another aspect of the present disclosure provides resinous materials for use in making extruded structures of insulative cellular non-aromatic polymeric materials. Yet another aspect of the present disclosure provides an extrudate comprising an insulative cellular non-aromatic polymeric material. Yet another aspect of the present disclosure provides a material structure formed from an insulative cellular non-aromatic polymeric material. Additional aspects of the present disclosure provide containers formed from insulative cellular non-aromatic polymeric materials.

In an exemplary embodiment, the formulation includes at least two polymeric materials. In an exemplary embodiment, the primary or base polymer comprises high melt strength polypropylene with long chain branching. In an exemplary embodiment, the polymeric material also has a non-uniform dispersion. Growth occurs by substituting a substituent (such as a hydrogen atom) on a monomeric subunit with another covalently bonded chain of the polymer, or in the case of a graft copolymer, another type of chain chain branching. For example, chain transfer reactions during polymerization can cause branching of the polymer. Long chain branching is branching that renders polymer side chains longer than the average critical entanglement distance of linear polymer chains. Long chain branching is generally understood to include polymer chains having at least 20 carbon atoms, depending on the specific monomer structure used for polymerization. Another example of branching is by crosslinking the polymer after the polymerization reaction is complete. Some long chain branched polymers are formed without crosslinking. Polymer chain branching can have a significant impact on material properties. Originally known as the polydispersity index, dispersity is a measurement term used to characterize the degree of polymerization. For example, free radical polymerization produces free radical monomer subunits attached to other free radical monomer subunits to produce a distribution of polymer chain lengths and polymer chain weights. Different types of polymerization reactions, such as living polymerization, stepwise polymerization, and free radical polymerization, result in different dispersity values due to specific reaction mechanisms. The degree of dispersion is determined as the ratio of weight average molecular weight to number average molecular weight. A uniform degree of dispersion is generally understood to mean a value close to or equal to 1. A non-uniform degree of dispersion is generally understood to mean a value greater than two. The final choice of polypropylene material may take into account the properties of the final material, additional materials required during formulation, and conditions during the extrusion process. In an exemplary embodiment, the high melt strength polypropylene may be capable of holding a gas (as discussed below), producing a desired cell size, having a desired surface smoothness, and having an acceptable level of off-odor ( material, if any).

An illustrative example of a suitable polypropylene base resin is DAPLOY ^™ WB140 homopolymer (commercially available from Borealis A/S), a high melt strength structurally isomerically modified polypropylene homopolymer (Melt strength = 36 (as tested according to ISO 16790 incorporated herein by reference), melting temperature = 325.4°F (163°C) (using ISO 11357 incorporated herein by reference)).

Polyaris DAPLOY ^TM WB140 characteristics (as described in the Polyaris product brochure):

Other polypropylene polymers with suitable melt strength, branching, and melting temperature can also be used. Several base resins can be used and mixed together.

In certain exemplary embodiments, a secondary polymer may be used with the base polymer. The secondary polymer can be, for example, a polymer having sufficient crystallinity. The secondary polymer may also be, for example, a polymer having sufficient crystallinity and melt strength. In exemplary embodiments, the secondary polymer may be at least one crystalline polypropylene homopolymer, impact polypropylene copolymer, mixtures thereof, or the like. An illustrative example is a highly crystalline polypropylene homopolymer (commercially available as F020HC from Braskem). Another illustrative example is an impact polypropylene copolymer commercially available as PRO-FAXSC204 ^™ (available from LyndellBasell Industries Holdings, BV). Another illustrative example is HomoPP-INSPIRE222 available from Blasco Corporation. Another illustrative example is a commercially available polymer known as PP527K available from Sabic. Another illustrative example is a polymer commercially available from LyondellBasell Industries as XA-11477-48-1. In one aspect, the polypropylene may have a high degree of crystallinity, ie, a content of crystalline phase exceeding 51% (as tested using differential scanning calorimetry) at a cooling rate of 10°C/min. In an exemplary embodiment, several different secondary polymers may be used and mixed together.

In an exemplary embodiment, the secondary polymer may be or may include polyethylene. In exemplary embodiments, the secondary polymer may include low density polyethylene, linear low density polyethylene, high density polyethylene, ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, ethylene-acrylic acid Copolymers, polymethyl methacrylate mixtures of at least two of the foregoing, and the like. As discussed further below, the use of non-polypropylene materials may affect recyclability, thermal insulation, microwavability, impact resistance, or other properties.

One or more nucleating agents are used to provide and control nucleation points to facilitate the formation of cells, bubbles, or voids in the molten resin during the extrusion process. Nucleating agents refer to chemical or physical materials that provide sites for cell formation in a molten resin mixture. Nucleating agents can be physical or chemical agents. Suitable physical nucleating agents have the desired particle size, aspect ratio, top-cut characteristics, shape and surface compatibility. Examples include, but are not limited to, talc, CaCO3, mica, kaolin, chitin, aluminosilicates, graphite, cellulose, and mixtures _of at least two of the foregoing. A nucleating agent may be blended with the polymer resin formulation introduced into the hopper. Alternatively, the nucleating agent may be added to the molten resin mixture in the extruder. When the chemical reaction temperature is reached, the nucleating agent acts to enable the formation of air bubbles, forming cells in the molten resin. An illustrative example of a chemical blowing agent is citric acid or a citric acid-based material. Upon decomposition, the chemical blowing agent forms small gas bubbles that further serve as nucleation sites for the growth of larger cells from the physical blowing agent or other types of blowing agents. A representative example is Hydrocerol ^™ CF-40E ^™ (commercially available from Clariant Corporation), which contains citric acid and a crystal nucleating agent. Another representative example is Hydrocerol ^™ CF-05E ^™ (commercially available from Clariant Corporation), which contains citric acid and a crystal nucleating agent. In illustrative examples, one or more catalysts or other reactants may be added to accelerate or facilitate cell formation.

In certain exemplary embodiments, one or more blowing agents may be incorporated. Blowing agent refers to a physical or chemical material (or combination of materials) that acts to expand the nucleation sites. Nucleating and blowing agents can work together. Blowing agents work to reduce density by forming cells in the molten resin. A blowing agent can be added to the molten resin mixture in the extruder. Representative examples of physical blowing agents include, but are not limited to, carbon dioxide, nitrogen, helium, argon, air, water vapor, pentane, butane, other alkane mixtures of the foregoing, and the like. In certain exemplary embodiments, processing aids that increase the solubility of the physical blowing agent may be used. Alternatively, the physical blowing agent may be a hydrofluoroalkane such as 1,1,1,2-tetrafluoroethane (also known as R134a), a hydrofluoroolefin such as but not limited to 1,3,3, 3-Tetrafluoropropene (also known as HFO-1234ze), or other haloalkane or haloalkane refrigerants. The choice of blowing agent can be made taking into account environmental influences.

In an exemplary embodiment, the physical blowing agent is typically a gas that is introduced in liquid form under pressure into the molten resin through ports in the extruder as shown in FIG. 1 . As the molten resin passes through the extruder and die, the pressure is reduced, causing the physical blowing agent to change from a liquid phase to a gas phase, thereby forming cells in the extruded resin. Excess gas is ejected after extrusion, while the remaining gas is trapped in the cells of the extrudate.

Chemical blowing agents are materials that degrade or react to produce gas. Chemical blowing agents can be endothermic or exothermic. Chemical blowing agents typically degrade at specific temperatures to decompose and release gas. In one aspect, the chemical blowing agent may be one or more materials selected from the group consisting of azodicarbonamide, azobisisobutyronitrile, benzenesulfonyl Hydrazine (benzenesulfonhydrazide), 4,4-phenolsulfonylsemicarbazide, p-toluenesulfonylsemicarbazide, barium azodicarboxylate, N,N'-dimethyl-N,N'-dinitroso-p-phenylene Diformamide, trihydrazinotriazine, methane, ethane, propane, n-butane, isobutane, n-pentane, isopentane, neopentane, fluoromethane, perfluoromethane, fluoroethane, 1 ,1-difluoroethane, 1,1,1-trifluoroethane, 1,1,1,2-tetrafluoro-ethane, pentafluoroethane, perfluoroethane, 2,2-difluoropropane , 1,1,1-trifluoropropane, perfluoropropane, perfluorobutane, perfluorocyclobutane, methyl chloride, methylene chloride, ethyl chloride, 1,1,1-trichloroethane, 1, 1-dichloro-1-fluoroethane, 1-chloro-1,1-difluoroethane, 1,1-dichloro-2,2,2-trifluoroethane, 1-chloro-1,2, 2,2-tetrafluoroethane, trichlorofluoromethane, dichlorodifluoromethane, trichlorotrifluoroethane, dichlorotetrafluoroethane, chloroheptafluoropropane, dichlorohexafluoropropane, methanol, ethanol, n-propane alcohol, isopropanol, sodium bicarbonate, sodium carbonate, ammonium bicarbonate, ammonium carbonate, ammonium nitrite, N,N'-dimethyl-N,N'-dinitrosoterephthalamide, N, N'-Dinitrosopentamethylenetetramine, azobisisobutylonitrile, azocyclohexanenitrile, azodiaminobenzene, benzenesulfonylhydrazide, toluenesulfonylhydrazide, p,p' -Oxybis(benzenesulfonyl hydrazide), diphenylsulfone-3,3'-disulfonyl hydrazide, calcium azide, 4,4'-diphenyldisulfonyl azide, and p-toluenesulfonyl azide.

In one aspect of the present disclosure, when a chemical blowing agent is used, the chemical blowing agent can be incorporated into the resin formulation fed to the hopper.

In one aspect of the present disclosure, the blowing agent may be a decomposable material that forms a gas when decomposed. Representative examples of such materials are citric acid or citric acid-based materials. In one exemplary aspect of the present disclosure, it is possible to use a mixture of physical and chemical blowing agents.

In one aspect of the present disclosure, at least one slip agent can be incorporated into the resin mixture to help increase production rates. Slip agents (also known as processing aids) are the term used to describe a general class of materials that are added to the resin mixture and provide surface lubrication to the polymer during and after conversion. Slip agents can also reduce or eliminate die drool. Representative examples of slip agent materials include amides of fats or fatty acids such as, but not limited to, erucamide and oleamide. In one exemplary aspect, oleamide (monounsaturated C ₁₈ ) to erucamide (C ₂₂ monounsaturated) can be used. Other representative examples of slip agent materials include low molecular weight amides and fluoroelastomers. Combinations of two or more slip agents can be used. The slip agent may be provided in the form of masterbatch granules and blended with the resin formulation. An example of a slip agent is commercially available as AMPACET ^™ 102109 SlipPEMB. Another example of a commercially available slip agent is AMAPACET ^™ 102823 processing aid PEMB.

One or more additional components and additives may optionally be incorporated, such as, but not limited to, impact modifiers, colorants such as, but not limited to, titanium dioxide, and compound regrinds. An example of a commercially available colorant is Blue-white colorant. Another example of a commercially available colorant is j11 white colorant.

The polymeric resin can be blended and melted with any additional desired components to form a resin formulation mixture.

In addition to surface topography and morphology, another factor found to be beneficial in obtaining wrinkle-free, high-quality insulating cups is the anisotropy of the insulating cellular non-aromatic polymer strips. The aspect ratio is the ratio of the major axis to the minor axis of the cell. As evidenced by microscopy, in one exemplary embodiment, the average cellular The hole size is about 0.0362 inches (0.92 mm) wide by about 0.0106 inches (0.27 mm) high. Thus, the machine direction cell size aspect ratio is about 3.5. The average cell size in the transverse direction (across the web or transverse direction) was about 0.0205 inches (0.52 mm) wide and about 0.0106 inches (0.27 mm) high. Therefore, the horizontal aspect ratio is 1.94. In one exemplary embodiment, it was found that the desired average aspect ratio of the cells was between about 1.0 and about 3.0 for the strip to withstand compressive forces during cup formation. In an exemplary embodiment, the desired average aspect ratio of the cells is between about 1.0 and about 2.0.

The ratio of cell length in the machine direction to the cross direction was used as a measure of the anisotropy of the extruded ribbon. In an exemplary embodiment, the strips of insulative cellular non-aromatic polymeric material may be biaxially oriented with an anisotropy coefficient in the range between about 1.5 and about 3. In an exemplary embodiment, the coefficient of anisotropy is about 1.8.

If the circumference of the cup is aligned with the machine direction 67 of the extruded strip 82, deep wrinkles having a depth in excess of about 200 microns typically form on the inner surface of the cup when the cell aspect ratio exceeds about 3.0, such that Cups are not available. Unexpectedly, it was found in one exemplary embodiment that if the circumference of the cup is aligned transversely to the extruded strip 82 (which may be characterized by a cell aspect ratio of less than about 2.0), No deep folds formed on the inside of , indicating that the transverse direction of the extruded strip 82 is more resistant to compressive forces during cup formation.

One possible reason for the greater compressibility of extruded ribbons in which cells have an aspect ratio below about 2.0 in the circumferential direction of the cup (e.g., in the transverse direction) may be attributable to the lower stress density of cells with larger radii . Another possible reason may be that a larger aspect ratio of the cells may imply a larger slenderness ratio of the cell walls, which is inversely proportional to the buckling strength. Folding the strips in compression mode produces wrinkles that can be approximated as buckling of the cell walls. For cell walls with longer lengths, the slenderness ratio (length to diameter) can be greater. Yet another possible factor in relieving compressive stress could be more favorable packing of polymer chains in the cell walls in the transverse direction, allowing the polymer chains to rearrange under compressive force. It is expected that the polymer chains are preferably oriented in the machine direction 67 and packed more closely.

In an exemplary embodiment, the alignment of the circumference of the formed cup along the direction of the extruded strand has a cell aspect ratio of less than about 2.0. Thus, having an extruded ribbon surface with a domain size of less than about 100 Angstroms facing the interior of the cup can provide the advantageous result of achieving the desired surface topography with defects less than about 5 microns deep.

In one aspect of the present disclosure, the polypropylene resin (either the base resin or the combined base and secondary resins) can have a density in the range of about 0.01 g/cm ³ to about 0.19 g/cm ³ . In an exemplary embodiment, the density may range from about 0.05 g/cm ³ to about 0.19 g/cm ³ . In an exemplary embodiment, the density may range from about 0.1 g/cm ³ to about 0.185 g/cm ³ .

In an alternative exemplary embodiment, polylactic acid materials, such as, but not limited to, polylactic acid materials derived from food-based materials such as cornstarch, may be used instead of polypropylene as the primary polymer. In an exemplary embodiment, polyethylene may be used as the primary polymer.

In an exemplary aspect of the present disclosure, formulations for materials useful in forming insulative cellular non-aromatic polymeric materials include the following: at least one primary resin including a high melt strength long chain branched polypropylene), at least one secondary resin (including highly crystalline polypropylene homopolymer or impact copolymer), at least one nucleating agent, at least one blowing agent, and at least one slip agent. Optionally, colorants can be incorporated.

The formulation can be introduced into the extruder via a hopper such as the one shown in Figure 1 . During the extrusion process, the formulation is heated and melted to form a molten resin mixture. In an exemplary embodiment, at least one physical blowing agent is introduced into the molten resin mixture through one or more ports in the extruder. The molten resin mixture and gas are then extruded through a die.

In another exemplary embodiment, the formulation may contain both at least one chemical blowing agent and at least one physical blowing agent.

Cups or other containers or structures may be formed from the sheet according to conventional equipment and methods.

For purposes of non-limiting illustration only, forming a cup from exemplary embodiments of the materials disclosed herein will be described; however, the container may be in any of a variety of possible shapes or configurations or for a variety of Applications such as (but not limited to) conventional drinking cups, storage containers, bottles or the like. For purposes of non-limiting illustration only, a liquid beverage will be used as the material that may be held by the container; however, the container may hold liquid, solid, gel, combinations thereof, or other materials.

Material forming method 100 is shown, for example, in FIG. 1 . As shown in FIG. 1 , material formation process 100 extrudes a non-aromatic polymeric material into a sheet or ribbon 82 of insulative cellular non-aromatic polymeric material. As an example, material forming method 100 uses a tandem extrusion technique in which first extruder 111 and second extruder 112 cooperate to extrude strip 82 of insulative cellular non-aromatic polymeric material.

As shown in FIG. 1 , a formulation 101 of insulative cellular non-aromatic polymeric material 82 is loaded into a hopper 113 coupled to a first extruder 111 . Formulation 101 may be in the form of pellets, granular flakes, powders, or other suitable forms. The formulation 101 of insulative cellular non-aromatic polymeric material is moved from the hopper 113 by a screw 114 included in the first extruder 111 . As shown in FIG. 1 , the formulation 101 is converted into a molten resin 102 in a first extrusion zone of a first extruder 111 by applying heat 105 and pressure from a screw 114 . In an exemplary embodiment, physical blowing agent 115 may be introduced and mixed into molten resin 102 after molten resin 102 is formed. In an exemplary embodiment, as discussed further herein, the physical blowing agent may be a gas that is introduced as a pressurized liquid via port 115A and mixed with molten resin 102 to form a molten extruded resin Mixture 103, as shown in FIG. 1 .

As shown in FIG. 1 , the extruded resin mixture 103 is conveyed by a screw 114 into a second extrusion zone included in a second extruder 112 . Here, the extruded resin mixture 103 is further processed by a second extruder 112 and then exits through an extrusion die 116 coupled to one end of the second extruder 112 to form the extrudate 104 . As extruded resin mixture 103 passes through extrusion die 116 , gas 115 comes out of solution in extruded resin mixture 103 and begins to form cells and expand to form extrudate 104 . As in the exemplary embodiment shown in FIG. 1 , the extrudate 104 may be formed through an annular extrusion die 116 to form a tubular extrudate. As shown in FIG. 1 , a slitter 117 then cuts the extrudate 104 to form sheets or strips 82 of insulative cellular non-aromatic polymeric material.

Extrudate refers to the material that exits the extrusion die. The extrudate mass can be extruded through an extruder in the form of, for example, but not limited to, flakes, strips, tubes, strands, pellets, granules, or polymer-based formulations as described herein Other structures produced by the die. For purposes of illustration only, sheets may be mentioned as representative extrudate structures that may be formed, but are intended to include structures discussed herein. The extrudate may be further formed into any of a variety of end products such as, but not limited to: cups, containers, trays, wraps, rolls of strips of insulative cellular non-aromatic polymeric material, or analog.

As an example, a strip 82 of insulative cellular non-aromatic polymeric material is wound to form a roll of insulative cellular non-aromatic polymeric material and stored for later use. However, a strip 82 of insulative cellular non-aromatic polymeric material to be used in accordance with the cup forming method is within the scope of the present disclosure. In one illustrative example, a strip 82 of insulative cellular non-aromatic polymer material is laminated with a skin layer having a film and ink layer printed on the film for high quality graphics.

As shown in Figures 2 and 3, the insulative cup 10 is formed using a strip 82 of insulative cellular non-aromatic polymer material. For example, an insulating cup 10 includes a body 11 having a sleeve-like side wall 18 and a bottom 20 coupled to the body 11 to cooperate with the side wall 18 to form a cup for storing food, liquid, or any suitable container. The interior area 14 of the product is shown in FIG. 2 . The body 11 also includes a bead 16 coupled to the upper end of the side wall 18 and a bottom bracket 17 coupled to the lower end of the side wall 18 and the bottom 20 , as shown in FIGS. 2 and 7 .

Body 11 is formed from a strip 82 of insulative cellular non-aromatic polymer material as disclosed herein. In accordance with the present disclosure, strips 82 of insulative cellular non-aromatic polymeric material are configured via the application of pressure and heat (although in an exemplary embodiment, configuration may occur without the application of heat) to provide Means for effecting localized plastic deformation in at least one selected region to provide an insulative cellular non-aromatic polymer material sheet having a first density in a first portion of the selected region of the body 11 without rupturing the sheet. The plastically deformed first sheet section and the second sheet section having a second density lower than said first density in an adjacent second portion of the selected area of the body 11 such that a predetermined density is maintained in the body 11. insulation characteristics.

As shown in FIGS. 2 , 5 and 6 , a first region 101 of selected regions of the body 11 where localized plastic deformation is enabled by the insulating cellular non-aromatic polymer material is in the sleeve-like sidewall 18 . As shown in FIGS. 2 , 5 and 6 , the sleeve-shaped sidewall 18 includes a vertical inner tab 514 , a vertical outer tab 512 and a vertical fence 513 . Upstanding internal tabs 514 are arranged to extend upwardly from the base 20 and are configured to provide said first sheet segments having said first density in said first region 101 of selected regions of body 11 . As shown in FIG. 6 , the upright outer tab 512 is arranged to extend upwardly from the base 20 and mate with the upright inner tab 514 along the interface I between the upright outer tab and the upright inner tab. The vertical fence 513 is arranged to interconnect the vertical inner tab 514 and the vertical outer tab 512 with the surrounding inner region 14 . As shown in FIGS. 2-5 , the standing fence 513 is configured to provide said second sheet segments having said second density in said first region 101 of selected regions of body 11 and is in contact with a standing fence 513 . The vertical inner tab 514 and the vertical outer tab 512 cooperate to form the sleeve-shaped side wall 18.

As shown in FIGS. 2 , 4 , 5 and 7 , a second region 102 of selected regions of the body 11 in which localized plastic deformation can be achieved by a sheet of insulative cellular non-aromatic polymer material is in the body 11 Included curling 16 in. Bead 16 is coupled to the upper end of sleeve-like sidewall 18 in spaced relation to base 20 and frames an opening into interior region 14 . As shown in FIGS. 2 , 4 , 5 and 7 , the curl 16 includes an inner curl tab 164 , an outer curl tab 162 and a curl lip 163 . The inner rolled tab 164 is configured to provide the first sheet segment in the second region 102 in selected regions of the body 11 . The inner rolled tab 164 is coupled to the upper end of an upstanding outer tab 512 included in the sleeve-shaped sidewall 18 . The outer rolled tab 162 is coupled with the upper end of the upstanding inner tab 514 included in the sleeve-like sidewall 18 and with the outer facing surface of the inner rolled tab 164 . The rolled lip 163 is arranged to interconnect the oppositely facing sides of each of the inner rolled tab 164 and the outer rolled tab 162 . As shown in FIG. 2 , rolled lip 163 is configured to provide said second sheet segment having said second density in said second region 102 of selected regions of body 11 and is in contact with an inner rolled interface. Sheet 164 and outer rolled tab 162 cooperate to form bead 16 .

As shown in FIGS. 2 , 5 and 8 , a third region 103 of selected regions of the body 11 in which localized plastic deformation can be achieved by a sheet of insulative cellular non-aromatic polymeric material is a region comprised by the body 11 in the bottom bracket. Bottom bracket 17 is coupled to the lower end of sleeve-like sidewall 18 in spaced relation to bead 16 and is coupled to base 20 to support base 20 in a fixed position relative to sleeve-like sidewall 18 to form an interior Area 14. Bottom bracket 17 includes web support ring 126 , bottom fixing flange 26 , and web 25 . A web support ring 126 is coupled to the lower end of the sleeve-like sidewall 18 and is configured to provide said second laminar segments having said second density in said third region 103 of selected regions of body 11 . Bottom securing flange 26 is coupled to bottom 20 and is arranged to be surrounded by web support ring 126 . The web 25 is arranged to interconnect the bottom fixing flange 26 with the web support ring 126 . The web 25 is configured to provide said first sheet segments having said first density in said third region 103 of selected regions of the body 11 .

As shown in FIGS. 2 , 5 and 9 , a fourth region 104 of the selected regions of the body 11 where localized plastic deformation is enabled by a sheet of insulating cellular non-aromatic polymer material is at the bottom of the bottom bracket 17 in the fixing flange. Bottom securing flange 26 comprises a series of alternating upright thick and thin staves arranged in side-to-side relationship so as to extend upwardly from web 25 towards interior region 14 bounded by sleeve-like sidewall 18 and bottom 20 . The first of the vertical slabs 261 is configured to include a right side edge extending upwardly from the web 25 towards the interior region 14 . The second stave 262 of the vertical plank is configured to include a left side edge arranged to extend upwardly from the web 25 towards the interior region 14 and is aligned with the right side of the first stave 261 of the vertical plank. The sides are in spaced facing relationship. the first stave 260 of the vertical slab is arranged to interconnect the left edge of said first stave 261 of the vertical slab with the right edge of said second stave 262 of the vertical slab, and cooperate with the left and right sides to define a vertical channel 263 therebetween, which leads inwardly to the bottom mounting flange 26 and the base 20 included in and above the bottom mounting flange 26. The lower internal area is defined by the horizontal platform 21 . The first stave 260 of the standing thin stave is configured to provide the first sheet section in the fourth region 104 of selected regions of the main body 11 . Said first stave 261 of the standing slab is configured to provide said second sheet section in said fourth region 104 of selected regions of body 11 .

The compressibility of the insulative cellular non-aromatic polymer material used to create the insulative cup 10 renders the insulative cellular non-aromatic polymer material ready for mechanical assembly of the insulative cup 10 without other Limitations experienced by non-aromatic polymeric materials. The cellular nature of the material provides the insulating characteristics discussed below, while the ease of plastic deformation allows the material to grow without rupture. The plastic deformation experienced when the insulative cellular non-aromatic polymeric material is subjected to a pressure load serves to form a permanent set in the insulative cellular non-aromatic polymeric material upon removal of the pressure load. In some locations, permanently set locations are positioned so as to provide controlled aggregation of sheets of insulative cellular non-aromatic polymeric material.

Plastic deformation can also be used to create fold lines in the sheet to control the deformation of the sheet when acted upon during the assembly process. When deformation is present, the absence of material in the voids formed by the deformation provides relief for the material to readily fold at the deformed location.

A potentially unexpected feature of sheets of insulative cellular non-aromatic polymeric material formed as described herein is the high insulation value obtained for a given thickness. See eg Examples 1 and 2 below.

A potential feature of a cup formed from the insulative cellular non-aromatic polymer material according to exemplary embodiments of the present disclosure is that the cup has low material loss. Furthermore, the materials of the present disclosure can have significantly low outgassing when subjected to heating from conventional kitchen type microwave ovens for periods of up to several minutes.

Another potential feature of a cup formed from an insulative cellular non-aromatic polymer material according to the present disclosure is that the cup can be placed in and subjected to a conventional residential or commercial dishwasher cleaning cycle (top rack )) without significant structural or material damage or adverse effects on the properties of the material. This feature is in contrast to beaded expanded polystyrene cups or containers that can be damaged under similar cleaning processes. Thus, cups made according to one aspect of the present disclosure can be cleaned and reused.

Another potential feature of articles formed from insulative cellular non-aromatic polymeric materials according to various aspects of the present disclosure is that the articles are recyclable. Recyclable means that material (such as regrind) can be added back to the extrusion or other forming process without separating the material components, i.e., items formed from said material do not need to be treated to remove part of the material before re-entering the extrusion process. one or more materials or components. For example, cups with a printed film layer laminated to the outside of the cup may be recyclable if one does not need to separate the film layer before the cup is ground into particles. In contrast, paper-wrapped expanded polystyrene cups may not be recyclable because the polystyrene material cannot actually be used as material in forming expanded polystyrene cups, even though the cup material may possibly form for another product. As a further example, a cup formed from non-expanded polystyrene material having a non-styrene printed film layer adhered thereto may be considered non-recyclable because it would require separation of the polystyrene cup material from the Non-styrene film layers, which are introduced into the extrusion process as part of the regrind would be undesirable.

The recyclability of articles formed from the insulative cellular non-aromatic polymeric materials of the present disclosure minimizes the amount of single-use waste generated. In contrast, beaded expanded polystyrene cups disintegrate into beads and therefore generally cannot be easily reused in a manufacturing process using the same material from which the article is formed. Also, paper cups that typically have extrusion-coated plastic layers or plastic laminates for liquid resistance are generally not recyclable because the different materials (paper, adhesive, and film, plastic) are often not practical to recycle commercially Separation during operation.

A potential feature of a cup or other article formed from material according to one aspect of the present disclosure (non-lamination process) is that the insulative cellular non-aromatic polypropylene sheet (before forming the cup or during the formation of the cup, depending on Depending on the manufacturing method used), the outer wall surface (or the inner wall surface or both) can accept the printing of high-resolution graphics. Conventional beaded expanded polystyrene cups have surfaces that are typically not smooth enough to accept printing other than low resolution graphics. Similarly, known uncoated paper cups also typically do not have a smooth enough surface for such high resolution graphics. Paper cups can be coated to have the desired surface finish and to achieve high resolution. Paper is difficult to achieve insulation levels and requires a designed air gap incorporated into or associated with the cup to achieve insulation, such as a sleeve that slides onto and fits over a portion of the cup. So the solution is to use low resolution printing, to laminate a printed film onto the outer wall, or to have a printing sleeve (adhesive or removable) that is inserted outside said outer wall, or to coat the paper so that Accepts high-resolution graphics.

A potential feature of a cup formed from the insulative cellular non-aromatic polymer material according to one aspect of the present disclosure is that it has unexpected strength as measured by stiffness. Stiffness is a measure that is performed and measures the stiffness of a material at room temperature as well as elevated temperature (eg, by filling a cup with hot liquid), reduced temperature (eg, by filling a quilt with cold liquid). The strength of the cup material is important to reduce the possibility of the user deforming the cup and the lid popping open or the lid or sidewall seal leaking.

As described below, a potential feature of a cup formed from an insulative cellular non-aromatic polymer material according to the present disclosure, as measured by standard impact testing, is that the sleeve is resistant to impact by, for example, straws, forks, spoons, Piercings caused by fingernails or the like. The test material showed substantially higher impact resistance when compared to the beaded expanded polystyrene cup. Thus, a cup formed as described herein can reduce the likelihood of perforation and leakage of hot liquid to the user.

A feature of cups with compressed sides and seams formed from materials according to an aspect as described herein is that a greater number of such cups can be nested for a given sleeve length because the seams are thinner and the sidewall angles can be adjusted. Minimized (ie closer to 90° relative to the bottom of the cup) while providing sufficient air gap to allow easy de-nesting. Conventional seam-forming cups with substantially thicker seams than sidewalls require larger sidewall angles (and air gaps) in order to allow de-nesting, resulting in fewer cups being nested for a given sleeve length. cup.

Cups formed from materials according to aspects of the present disclosure can be characterized by a rim that can have a cross-sectional profile of less than about 0.170 inches (4.318 mm), which is attributable to localized cell deformation and compression. Such a small profile is more aesthetically pleasing than a larger profile.

Cups formed from materials according to an aspect of the present disclosure can be characterized in that the rim diameter can be the same for cups with different volumes, thereby enabling one lid size to be used for different cup sizes (assuming the rim outer diameter is the same ). Thus, the number of different sized caps in stock and in use can be reduced.

The material formulation may have properties that allow the flakes to compress without breaking.

A potential feature of a cup formed from an insulative cellular non-aromatic polymer material according to one aspect of the present disclosure is that the cup can vent a physical blowing agent in gaseous form and undergo gas exchange with the surrounding environment to fill in the in the foam pores. As a result, blowing agents or mixtures of blowing agents can be detected.

A potential feature of a cup formed from an insulative cellular non-aromatic polymer material according to one aspect of the present disclosure is that the cup can undergo crystallization solidification due to cooling with ambient air and environment. As a result, the cup stiffness will increase with unexpected strength.

The insulative cellular non-aromatic polymeric material of the present disclosure can be formed into ribbons that can be wrapped around other structures. For example, a strip of material according to an aspect of the present disclosure that can be used as a wrapping material can be formed and wrapped around a pipe, conduit, or other structure to provide improved insulation. The sheet or tape may have a layer of adhesive (eg pressure sensitive adhesive) applied to one or both sides. The strip can be wound onto a roll. Optionally, the strap may have a release liner associated therewith to make it easier to unwind the strap from the roll. For example, the polymer formulation can be adapted by using one or more polypropylene or other polyolefin materials that are sufficiently flexible to provide the necessary flexibility to form wraps or rollable strips to enable The extruded sheet is made flexible enough to be wound on a roll. The insulating cellular non-aromatic polymer material can be formed into a sleeve that can be inserted over the cup to provide additional insulation.

In exemplary embodiments, sheets formed from the insulative cellular non-aromatic polymeric materials of the present disclosure can be cut or sheeted at a die and used as bulk insulators.

The formulations and insulative cellular non-aromatic polymeric materials of the present disclosure meet a long-felt need for a material that can be formed into an article, such as a cup, that includes many, if not all, of the following features: insulating properties, ease of recycling resistance, puncture resistance, shatter resistance, microwaveability, and other characteristics as discussed herein. Other formulations have failed to provide materials that achieve the combination of features as reflected in the appended claims. This failure is the result of features related to competing design choices. As an example, other formulations have produced materials and structures from which, based on design choices, they are insulating, but suffer from poor puncture resistance, ineffective recycling, and lack of microwavability. In comparison, the formulations and materials disclosed herein overcome the deficiencies of other formulations and materials through the use of insulating cellular non-aromatic polymeric materials. Reference is made here to U.S. Application Serial No. 13/491,007, filed June 7, 2012, and entitled "INSULATED CONTAINER," which discloses articles formed from such insulating cellular non-aromatic polymeric materials (such as a cup), said application is hereby incorporated herein in its entirety.

It is within the scope of the present disclosure to select the amount of nucleating agent to be one of the following values: about 0%, 0.5%, 1%, 1.5%, 2%, 2.5% by weight of the total formulation of the polymer layer %, 3%, 4%, and 5%. It is still within the scope of the disclosure that the weight percent (w/w) of the nucleating agent (eg, talc (eg, HT4HP or HT6HP)) falls within one of a number of different ranges. In the first set of ranges, the weight percent of nucleating agent is one of the following ranges: about 0.1% to 20% (w/w), 0.25% to 20%, 0.5% to 20%, 0.75% to 20%, 1% to 20%, 1.5% to 20%, 2% to 20%, 2.5% to 20%, 3% to 20%, 4% to 20%, 4.5% to 20%, and 5% to 20%. In a second set of ranges, the range of nucleating agent is one of the following ranges: about 0.1% to 10%, 0.25% to 10%, 0.5% to 10%, 0.75% to 10%, 1% to 10%, 1.5% to 10%, 2% to 10%, 3% to 10%, 4% to 10%, and 5% to 10%. In a third set of ranges, the range of the nucleating agent is one of the following ranges: about 0.1% to 5%, 0.25% to 5%, 0.5% to 5%, by weight of the total formulation of the polymer layer 0.75% to 5%, 1% to 5%, 1.5% to 5%, 2% to 5%, 2.5% to 5%, 3% to 5%, 3.5% to 5%, 4% to 5%, and 4.5% % to 5%. In embodiments, the polymeric material lacks nucleating agents.

The amount of chemical blowing agent can be one of several different values or fall within one of several different ranges. It is within the scope of the present disclosure to select the amount of chemical blowing agent to be one of the following values: about 0%, 0.1%, 0.5%, 0.75%, 1% by weight of the total formulation of the polymer layer , 1.5%, or 2%. It is within the scope of the present disclosure that the amount of physical nucleating agent in the formulation falls within one of a number of different ranges. In the first set of ranges, the range of the chemical blowing agent is one of the following ranges: about 0% to 5%, 0.1% to 5%, 0.25% to 5% by weight of the total formulation of the polymer layer , 0.5% to 5%, 0.75% to 5%, 1% to 5%, 1.5% to 5%, 2% to 5%, 3% to 5%, and 4% to 5%. In the second set of ranges, the range of the chemical blowing agent is one of the following ranges: about 0.1% to 4%, 0.1% to 3%, 0.1% to 2%, and 0.1% by weight percent of the total formulation to 1%. In a third set of ranges, the range of the chemical blowing agent is one of the following ranges: about 0.25% to 4%, 0.75% to 4%, 1% to 4% by weight of the total formulation of the polymer layer , 1.5% to 4%, 2% to 4%, 3% to 4%, 0% to 3%, 0.25% to 3%, 0.5% to 3%, 0.75% to 3%, 1% to 3%, 1.5 %, to 3%, 2% to 3%, 0% to 2%, 0.25% to 2%, 0.5%, to 2%, 0.75% to 2%, 1% to 2%, 1.5% to 2%, 0 % to 1%, 0.5% to 1%, and 0.75% to 1%. In one aspect of the present disclosure, when a chemical blowing agent is used, the chemical blowing agent can be incorporated into the material formulation added to the hopper.

The amount of slip agent can be one of several different values or fall within one of several different ranges. It is within the scope of the present disclosure to select the amount of slip agent to be one of the following values: about 0%, 0.5%, 1%, 2%, 3%, by weight percent of the total formulation of the polymer layer. 4%, 5%, 6%, 7%, 8%, 9%, or 10%. It is within the scope of the present disclosure that the amount of slip agent in the formulation falls within one of a number of different ranges. In the first set of ranges, the range of slip agent is one of the following ranges: about 0% to 10% (w/w), 0.5% to 10%, 1% by weight of the total formulation of the polymer layer % to 10%, 2% to 10%, 3% to 10%, 4% to 10%, 5% to 10%, 6% to 10%, 7% to 10%, 8% to 10%, and 9% to 10%. In a second set of ranges, the range of slip agent is one of the following ranges: about 0% to 9%, 0% to 8%, 0% to 7%, by weight percent of the total formulation of the polymer layer 0% to 6%, 0% to 5%, 0% to 4%, 0% to 3%, 0% to 2%, 0% to 1%, and 0% to 0.5%. In a third set of ranges, the slip agent range is one of the following ranges: about 0.5% to 5%, 0.5% to 4%, 0.5% to 3%, 0.5% to 2% by weight of the total formulation %, 1% to 2%, 1% to 3%, 1% to 4%, 1% to 5%, 2% to 3%, 2% to 4%, and 2% to 5%. In an embodiment, the formulation lacks slip agents.

The amount of colorant can be one of several different values or fall within one of several different ranges. It is within the scope of the present disclosure to select the amount of colorant as one of the following values: about 0%, 0.1%, 0.5%, 0.6%, 0.7%, 0.8% by weight of the total formulation of the polymer layer %, 0.9%, 1%, 1.5%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 15%, or 20%. It is within the scope of the disclosure that the amount of colorant in the formulation falls within one of a number of different ranges. In a first set of ranges, the colorant range is one of the following ranges: about 0% to 20% (w/w), 0% to 10%, 0% to 5%, and 0% to 4%. In a second set of ranges, the range of the colorant is one of the following ranges: about 0.1% to 4%, 0.25% to 4%, 0.5% to 4%, 0.75% by weight of the total formulation of the polymer layer % to 4%, 1% to 4%, 1.5% to 4%, 2% to 4%, 2.5% to 4%, and 3% to 4%. In a third set of ranges, the colorant range is one of the following ranges: about 0% to 3%, 0% to 2.5%, 0% to 2.25%, 0% to 2% by weight of the total formulation , 0% to 1.5%, 0% to 1%, 0% to 0.5%, 0.1% to 3.5%, 0.1% to 3%, 0.1% to 2.5%, 0.1% to 2%, 0.1% to 1.5%, 0.1 % to 1%, 1% to 5%, 1% to 10%, 1% to 15%, 1% to 20%, and 0.1% to 0.5%. In embodiments, the formulation lacks colorants.

In an illustrative embodiment, the polymeric material includes a primary base resin. In an illustrative embodiment, the base resin may include polypropylene. In an illustrative embodiment, the insulative cellular non-aromatic polymer material includes a polypropylene base resin, a polypropylene copolymer or homopolymer (or both) having a high melt strength. It is within the scope of the present disclosure to select the amount of base resin to be one of the following values: about 50%, 55%, 60%, 65%, 70%, 75% by weight of the total formulation of the polymer layer %, 80%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, 99.5%, and 99.9%. It is within the disclosure that the amount of base resin in the formulation falls within one of a number of different ranges. In the first set of ranges, the range of the base resin is one of the following ranges: about 50% to 99.9%, 70% to 99.9%, 80% to 99.9%, 85% by weight of the total formulation of the polymer layer % to 99.9%, 90% to 99.9%, 95% to 99.9%, 98% to 99.9%, and 99% to 99.9%. In the second set of ranges, the range of the base resin is one of the following ranges: about 85% to 99%, 85% to 98%, 85% to 95%, and 85% to 90%. In a third set of ranges, the range of the base resin is one of the following ranges: about 50% to 99%, 50% to 95%, 50% to 85%, 55% to 85% by weight of the total formulation , 80% to 90%, 80% to 95%, 90% to 99%, and 95% to 98%. Each of the values and ranges was achieved in Examples 1-12. As previously defined, any suitable primary base resin may be used.

In an illustrative embodiment, the polymeric material includes a secondary resin, where the secondary resin may be a polypropylene copolymer or homopolymer (or both). It is within the disclosure that the amount of the secondary base resin in the formulation falls within one of a number of different ranges. In the first set of ranges, the range of the base resin is one of the following ranges: about 0% to 50%, 0% to 30%, 0% to 25%, 0% by weight of the total formulation of the polymer layer % to 20%, 0% to 15%, 0% to 10%, and 0% to 5%. In the second set of ranges, the range of the secondary base resin is one of the following ranges: about 10% to 50%, 10% to 40%, 10% to 30% of the total formulation of the polymer layer by weight percent , 10% to 25%, 10% to 20%, and 10% to 15%. In a third set of ranges, the range of the secondary base resin is one of the following ranges: about 1% to 5% and 5% to 10% by weight percent of the total formulation. In an embodiment, the polymeric material lacks a secondary resin. In a specific embodiment, the secondary resin may be a high crystalline polypropylene homopolymer such as F020HC (available from Brasco) or PP527K (available from SABIC). In an embodiment, the polymeric material lacks a secondary resin.

The following numbered paragraphs define specific embodiments of the insulative cellular non-aromatic polymeric material of the present invention:

1) 50 - 99.9 wt% of at least one polypropylene base resin;

5 - 50 wt% of at least one polypropylene secondary resin;

0.01 wt% - 7 wt% of at least one nucleating agent selected from physical nucleating agents and chemical nucleating agents;

1-5 wt% of at least one slip agent; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

2) 55-90 wt% of at least one polypropylene base resin;

5 - 45 wt% of at least one polypropylene secondary resin;

0.01 wt% - 7 wt% of at least one nucleating agent selected from physical nucleating agents and chemical nucleating agents;

1-5 wt% of at least one slip agent; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

3) 70-90 wt% of at least one polypropylene base resin;

5 - 30 wt% of at least one polypropylene secondary resin;

0.01 wt% - 7 wt% of at least one nucleating agent selected from physical nucleating agents and chemical nucleating agents;

1-5 wt% of at least one slip agent; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

4) 75-90 wt% of at least one polypropylene base resin;

5 - 25 wt% of at least one polypropylene secondary resin;

0.01 wt% - 7 wt% of at least one nucleating agent selected from physical nucleating agents and chemical nucleating agents;

1-5 wt% of at least one slip agent; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

5) 75-90 wt% of at least one polypropylene base resin;

5 - 25 wt% of at least one polypropylene secondary resin;

0.01 wt% - 6 wt% of at least one nucleating agent selected from physical nucleating agents and chemical nucleating agents;

1 - 4 wt% of at least one slip agent; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

6) 75-90 wt% of at least one polypropylene base resin;

5 - 25 wt% of at least one polypropylene secondary resin;

0.01 - 0.25 wt% of at least one chemical nucleating agent;

0.1 - 5 wt% of at least one physical nucleating agent;

1 - 4 wt% of at least one slip agent; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

7) 75-90 wt% of at least one polypropylene base resin;

5 - 25 wt% of at least one polypropylene secondary resin;

0.01 - 0.2 wt% of at least one chemical nucleating agent;

0.1 - 2.5 wt% of at least one physical nucleating agent;

1 - 4 wt% of at least one slip agent; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

8) 76-90 wt% of at least one polypropylene base resin;

7.5 - 22.5 wt% of at least one polypropylene secondary resin;

0.01 - 0.2 wt% of at least one chemical nucleating agent;

0.1 - 2.5 wt% of at least one physical nucleating agent;

1 - 4 wt% of at least one slip agent; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

9) 78-90 wt% of at least one polypropylene base resin;

7.5 - 22.5 wt% of at least one polypropylene secondary resin;

0.01 - 0.2 wt% of at least one chemical nucleating agent;

0.1 - 2.5 wt% of at least one physical nucleating agent;

1 - 4 wt% of at least one slip agent; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

10) 78-90 wt% of at least one polypropylene base resin;

7.5 - 17.5 wt% of at least one polypropylene secondary resin;

0.01 - 0.15 wt% of at least one chemical nucleating agent;

0.2 - 2.5 wt% of at least one physical nucleating agent;

1 - 3 wt% of at least one slip agent; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

11) 78 - 88 wt% of at least one polypropylene base resin;

7.5 - 17.5 wt% of at least one polypropylene secondary resin;

0.01 - 0.15 wt% of at least one chemical nucleating agent;

0.2 - 2.5 wt% of at least one physical nucleating agent;

1 - 3 wt% of at least one slip agent;

0.1–2 wt% colorant; and

Optionally, the remainder of the formulation comprises one or more additives selected from impact modifiers and compound regrinds.

12) 78 - 88 wt% of at least one polypropylene base resin;

7.5 - 16 wt% of at least one polypropylene secondary resin;

0.01 - 0.15 wt% of at least one chemical nucleating agent;

0.2 - 2.5 wt% of at least one physical nucleating agent;

1 - 3 wt% of at least one slip agent;

0.1–2 wt% colorant; and

Optionally, the remainder of the formulation comprises one or more additives selected from impact modifiers and compound regrinds.

13) 79 - 88 wt% of at least one polypropylene base resin;

7.5 - 16 wt% of at least one polypropylene secondary resin;

0.03 - 0.15 wt% of at least one chemical nucleating agent;

0.2 - 2.5 wt% of at least one physical nucleating agent;

1 - 3 wt% of at least one slip agent;

0.1–1.5 wt% colorant; and

Optionally, the remainder of the formulation comprises one or more additives selected from impact modifiers and compound regrinds.

14) 79 - 88 wt% of at least one polypropylene base resin;

7.5 - 16 wt% of at least one polypropylene secondary resin;

0.03 - 0.15 wt% of at least one chemical nucleating agent;

0.2 - 2.5 wt% of at least one physical nucleating agent;

1.5 - 3 wt% of at least one slip agent;

0.1–1.5 wt% colorant; and

Optionally, the remainder of the formulation comprises one or more additives selected from impact modifiers and compound regrinds.

15) 80 - 88 wt% of at least one polypropylene base resin;

7.5–15% by weight of at least one polypropylene secondary resin;

0.05 - 0.15 wt% of at least one chemical nucleating agent;

0.3-2 wt% of at least one physical nucleating agent;

1.5 - 2.5 wt% of at least one slip agent; and

0.1–1.5% by weight of colorants;

16) 82 - 88 wt% of at least one polypropylene base resin;

7.5 - 12.5 wt% of at least one polypropylene secondary resin;

0.05 - 0.15 wt% of at least one chemical nucleating agent;

0.3-2 wt% of at least one physical nucleating agent;

1.5 - 2.5 wt% of at least one slip agent; and

0.3–1.3% by weight of colorants;

17) 84 - 88 wt% of at least one polypropylene base resin;

7.5 - 12.5 wt% of at least one polypropylene secondary resin;

0.07 - 0.15 wt% of at least one chemical nucleating agent;

0.3 - 1.5 wt% of at least one physical nucleating agent;

1.7 - 2.3 wt% of at least one slip agent; and

0.3–1.3% by weight of colorants;

18) 85 - 88 wt% of at least one polypropylene base resin;

8 - 12 wt% of at least one polypropylene secondary resin;

0.08 - 0.15 wt% of at least one chemical nucleating agent;

0.4 - 1.3 wt% of at least one physical nucleating agent;

1.7 - 2.3 wt% of at least one slip agent; and

0.3–1.3% by weight of colorants;

19) 85.5 - 87.5 wt% of at least one polypropylene base resin;

8.5–11.5 wt% of at least one polypropylene secondary resin;

0.09 - 0.15 wt% of at least one chemical nucleating agent;

0.4 - 1.3 wt% of at least one physical nucleating agent;

1.8 - 2.2 wt% of at least one slip agent; and

0.4–1.2 wt% colorant;

20) 86 - 87 wt% of at least one polypropylene base resin;

9-11 wt% of at least one polypropylene secondary resin;

0.1 - 0.14 wt% of at least one chemical nucleating agent;

0.5 - 1.1 wt% of at least one physical nucleating agent;

1.8 - 2.2 wt% of at least one slip agent; and

0.4–1.1% by weight of colorants;

In any numbered paragraphs (1)-(20) above, the at least one polypropylene base resin may be selected from high melt strength polypropylene resins and resins with long chain branching. Suitably, said at least one polypropylene base resin is a polypropylene homopolymer. More suitably, said at least one polypropylene base resin is available under the trade name DAPLOY WB140 (commercially available from Polyaris Corporation).

In any numbered paragraphs (1)-(20) above, the at least one polypropylene secondary resin may be a polypropylene homopolymer or a polypropylene copolymer. Exemplary materials include one or more of the following: high crystalline polypropylene homopolymer (available as F020HC from Blasco Corporation), impact polypropylene copolymer commercially available as PRO-FAXSc204 ^™ (available as available from LyondellBasell Industries, HomoPP-INSPIRE222 (available from Brasco), PP527K (available from SABIC), and XA-11477- 48-1. Suitably the polypropylene may have a high degree of crystallinity at a cooling rate of 10°C/min, ie a content of crystalline phase exceeding 51% (as measured using differential scanning calorimetry). More suitably, said at least one polypropylene secondary resin is a crystalline polypropylene homopolymer. Most suitably, said at least one polypropylene secondary resin is a crystalline polypropylene homopolymer available as F020HC from Brasco Corporation.

In any numbered paragraphs (1)-(20) above, the at least one nucleating agent may be selected from talc, kaolin, clay, chitin, aluminosilicate, graphite, cellulose, _CaCO and /or a physical nucleating agent of mica; and/or selected from citric acid or citric acid-based materials (such as HYDROCEROL ^™ CF-40E, available from Clariant, or HYDROCEROL ^™ CF-05E, available from Clariant ) chemical nucleating agent. In one embodiment, the at least one nucleating agent is a mixture of talc and HYDROCEROL ^™ CF-40E. In another embodiment, the at least one physical nucleating agent is talc (eg, Heritage Plastics HT4HP talc or MillikenHPR-803i fibers). In another embodiment, said at least one chemical nucleating agent is HYDROCEROL ^™ CF-40E.

In any numbered paragraphs (1)-(20) above, at least one slip agent may be selected from amides, fluoroelastomers, fatty or fatty acid amides such as erucamide and oleamide, and from oleyl ( Amides of monounsaturated C-18) to mustardyl (C-22 monounsaturated). In one embodiment, the at least one slip agent is selected from Ampacet 102823 processing aid PEMBLLDPE or Ampacet 102109 SlipPEMB. Suitably, said at least one slip agent is Amsett's 102823 processing aid PEMBLLDPE.

In any numbered paragraphs (1)-(20) above, the one or more colorants may be selected from any suitable colorants. In one embodiment, the colorant is selected from 11933-19 Titanium Oxide Colorant, Ampacet Blue-White Colorant, and Ampacet J11 White Colorant. Suitably, the colorant is 11933-19 Titanium oxide colorant or Ampacet blue-white colorant.

The following numbered paragraphs define specific embodiments of the insulative cellular non-aromatic polymeric material of the present invention:

21) 50 - 99.9 wt% of at least one polypropylene homopolymer base resin;

5 - 50 wt% of at least one polypropylene homopolymer secondary resin;

0.01 - 7 wt% of at least one nucleating agent selected from talc, kaolin, clay, chitin, aluminosilicate, graphite, cellulose, CaCO ₃ , mica, citric acid and citric acid-based s material;

1 - 5% by weight of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C-18 ) to mustardyl (C-22 monounsaturated) amides; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

22) 55 - 90 wt% of at least one polypropylene homopolymer base resin;

5 - 45 wt% of at least one polypropylene homopolymer secondary resin;

0.01 - 7 wt% of at least one nucleating agent selected from talc, kaolin, clay, chitin, aluminosilicate, graphite, cellulose, CaCO ₃ , mica, citric acid and citric acid-based s material;

1 - 5% by weight of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C-18 ) to mustardyl (C-22 monounsaturated) amides; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

23) 70 - 90 wt% of at least one polypropylene homopolymer base resin;

5 - 30 wt% of at least one polypropylene homopolymer secondary resin;

0.01 - 7 wt% of at least one nucleating agent selected from talc, kaolin, clay, chitin, aluminosilicate, graphite, cellulose, CaCO ₃ , mica, citric acid and citric acid-based s material;

1 - 5% by weight of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C-18 ) to mustardyl (C-22 monounsaturated) amides; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

24) 75 - 90 wt% of at least one polypropylene homopolymer base resin;

5 - 25 wt% of at least one polypropylene homopolymer secondary resin;

0.01 - 7 wt% of at least one nucleating agent selected from talc, kaolin, clay, chitin, aluminosilicate, graphite, cellulose, CaCO ₃ , mica, citric acid and citric acid-based s material;

1 - 5% by weight of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C-18 ) to mustardyl (C-22 monounsaturated) amides; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

25) 75 - 90 wt% of at least one polypropylene homopolymer base resin;

5 - 25 wt% of at least one polypropylene homopolymer secondary resin;

0.01 - 6 wt% of at least one nucleating agent selected from talc, kaolin, clay, chitin, aluminosilicate, graphite, cellulose, CaCO ₃ , mica, citric acid and citric acid-based s material;

1 - 4% by weight of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C-18 ) to mustardyl (C-22 monounsaturated) amides; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

26) 75 - 90 wt% of at least one polypropylene homopolymer base resin;

5 - 25 wt% of at least one polypropylene homopolymer secondary resin;

0.01 - 0.25 wt% of at least one chemical nucleating agent selected from citric acid and citric acid-based materials;

0.1 - 5 wt% of at least one physical nucleating agent selected from the group consisting of talc, kaolin, clay, chitin, aluminosilicate, graphite, cellulose, CaCO ₃ , and mica;

1 - 4% by weight of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C-18 ) to mustardyl (C-22 monounsaturated) amides; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

27) 75 - 90 wt% of at least one polypropylene homopolymer base resin;

5 - 25 wt% of at least one polypropylene homopolymer secondary resin;

0.01 - 0.2 wt% of at least one chemical nucleating agent selected from citric acid and citric acid-based materials;

0.1 - 2.5 wt% of at least one physical nucleating agent selected from the group consisting of talc, kaolin, clay, chitin, aluminosilicates, graphite, cellulose, CaCO ₃ , and mica;

1 - 4% by weight of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C-18 ) to mustardyl (C-22 monounsaturated) amides; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

28) 76 - 90 wt% of at least one polypropylene homopolymer base resin;

7.5 - 22.5 wt% of at least one polypropylene homopolymer secondary resin;

0.01 - 0.2 wt% of at least one chemical nucleating agent selected from citric acid and citric acid-based materials;

0.1 - 2.5 wt% of at least one physical nucleating agent selected from the group consisting of talc, kaolin, clay, chitin, aluminosilicates, graphite, cellulose, CaCO ₃ , and mica;

1 - 4% by weight of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C-18 ) to mustardyl (C-22 monounsaturated) amides; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

29) 78 - 90 wt% of at least one polypropylene homopolymer base resin;

7.5 - 22.5 wt% of at least one polypropylene homopolymer secondary resin;

0.01 - 0.2 wt% of at least one chemical nucleating agent selected from citric acid and citric acid-based materials;

0.1 - 2.5 wt% of at least one physical nucleating agent selected from the group consisting of talc, kaolin, clay, chitin, aluminosilicates, graphite, cellulose, CaCO ₃ , and mica;

1 - 4% by weight of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C-18 ) to mustardyl (C-22 monounsaturated) amides; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

30) 78 - 90 wt% of at least one polypropylene homopolymer base resin;

7.5 - 17.5 wt% of at least one polypropylene homopolymer secondary resin;

0.01 - 0.15 wt% of at least one chemical nucleating agent selected from citric acid and citric acid-based materials;

0.2 - 2.5 wt% of at least one physical nucleating agent selected from the group consisting of talc, kaolin, clay, chitin, aluminosilicate, graphite, cellulose, CaCO ₃ , and mica;

1 - 3% by weight of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C-18 ) to mustardyl (C-22 monounsaturated) amides; and

Optionally, the remainder of the formulation comprises one or more additives selected from colorants, impact modifiers and compound regrinds.

31) 78 - 88 wt% of at least one polypropylene homopolymer base resin;

7.5 - 17.5 wt% of at least one polypropylene homopolymer secondary resin;

0.01 - 0.15 wt% of at least one chemical nucleating agent selected from citric acid and citric acid-based materials;

0.2 - 2.5 wt% of at least one physical nucleating agent selected from the group consisting of talc, kaolin, clay, chitin, aluminosilicate, graphite, cellulose, CaCO ₃ , and mica;

1 - 3% by weight of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C-18 ) to mustardyl (C-22 monounsaturated) amides;

0.1–2 wt% colorant; and

Optionally, the remainder of the formulation comprises one or more additives selected from impact modifiers and compound regrinds.

32) 78 - 88% by weight of at least one polypropylene homopolymer base resin;

7.5 - 16 wt% of at least one polypropylene homopolymer secondary resin;

0.01 - 0.15 wt% of at least one chemical nucleating agent selected from citric acid and citric acid-based materials;

0.2 - 2.5 wt% of at least one physical nucleating agent selected from the group consisting of talc, kaolin, clay, chitin, aluminosilicate, graphite, cellulose, CaCO ₃ , and mica;

1 - 3% by weight of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C-18 ) to mustardyl (C-22 monounsaturated) amides;

0.1–2 wt% colorant; and

Optionally, the remainder of the formulation comprises one or more additives selected from impact modifiers and compound regrinds.

33) 79 - 88 wt% of at least one polypropylene homopolymer base resin;

7.5 - 16 wt% of at least one polypropylene homopolymer secondary resin;

0.03 - 0.15 wt% of at least one chemical nucleating agent selected from citric acid and citric acid-based materials;

0.2 - 2.5 wt% of at least one physical nucleating agent selected from the group consisting of talc, kaolin, clay, chitin, aluminosilicate, graphite, cellulose, CaCO ₃ , and mica;

1 - 3% by weight of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C-18 ) to mustardyl (C-22 monounsaturated) amides;

0.1–1.5 wt% colorant; and

Optionally, the remainder of the formulation comprises one or more additives selected from impact modifiers and compound regrinds.

34) 79 - 88 wt% of at least one polypropylene homopolymer base resin;

7.5 - 16 wt% of at least one polypropylene homopolymer secondary resin;

0.03 - 0.15 wt% of at least one chemical nucleating agent selected from citric acid and citric acid-based materials;

0.2 - 2.5 wt% of at least one physical nucleating agent selected from the group consisting of talc, kaolin, clay, chitin, aluminosilicate, graphite, cellulose, CaCO ₃ , and mica;

1.5 - 3% by weight of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C-18 ) to mustardyl (C-22 monounsaturated) amides;

0.1–1.5 wt% colorant; and

Optionally, the remainder of the formulation comprises one or more additives selected from impact modifiers and compound regrinds.

35) 80 - 88% by weight of at least one polypropylene homopolymer base resin;

7.5 - 15 wt% of at least one polypropylene homopolymer secondary resin;

0.05 - 0.15 wt% of at least one chemical nucleating agent selected from citric acid and citric acid-based materials;

0.3-2 wt% of at least one talc-based physical nucleating agent;

1.5 - 2.5% by weight of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C- 18) Amides to mustardyl (C-22 monounsaturated); and

0.1–1.5% by weight of colorants;

36) 82 - 88 wt% of at least one polypropylene homopolymer base resin;

7.5 - 12.5 wt% of at least one polypropylene homopolymer secondary resin;

0.05 - 0.15 wt% of at least one chemical nucleating agent selected from citric acid and citric acid-based materials;

0.3-2 wt% of at least one talc-based physical nucleating agent;

1.5 - 2.5% by weight of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C- 18) Amides to mustardyl (C-22 monounsaturated); and

0.3–1.3% by weight of colorants;

37) 84 - 88 wt% of at least one polypropylene homopolymer base resin;

7.5 - 12.5 wt% of at least one polypropylene homopolymer secondary resin;

0.07 - 0.15 wt% of at least one chemical nucleating agent selected from citric acid and citric acid-based materials;

0.3 - 1.5 wt% of at least one talc-based physical nucleating agent;

1.7 - 2.3 wt% of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C- 18) Amides to mustardyl (C-22 monounsaturated); and

0.3–1.3% by weight of colorants;

38) 85 - 88 wt% of at least one polypropylene homopolymer base resin;

8 - 12 wt% of at least one polypropylene homopolymer secondary resin;

0.08 - 0.15 wt% of at least one chemical nucleating agent selected from citric acid and citric acid-based materials;

0.4 - 1.3 wt% of at least one talc-based physical nucleating agent;

1.7 - 2.3 wt% of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C- 18) Amides to mustardyl (C-22 monounsaturated); and

0.3–1.3% by weight of colorants;

39) 85.5 - 87.5 wt% of at least one polypropylene homopolymer base resin;

8.5 - 11.5 wt% of at least one polypropylene homopolymer secondary resin;

0.09 - 0.15 wt% of at least one chemical nucleating agent selected from citric acid and citric acid-based materials;

0.4 - 1.3 wt% of at least one talc-based physical nucleating agent;

1.8 - 2.2 wt% of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C- 18) Amides to mustardyl (C-22 monounsaturated); and

0.4–1.2 wt% colorant;

40) 86 - 87 wt% of at least one polypropylene homopolymer base resin;

9 - 11 wt% of at least one polypropylene homopolymer secondary resin;

0.1 - 0.14 wt% of at least one chemical nucleating agent selected from citric acid and citric acid-based materials;

0.5 - 1.1 wt% of at least one talc-based physical nucleating agent;

1.8 - 2.2 wt% of at least one slip agent selected from amides, fluoroelastomers, amides of fats or fatty acids such as erucamide and oleamide, and from oleyl (monounsaturated C- 18) Amides to mustardyl (C-22 monounsaturated); and

0.4–1.1% by weight of colorants;

In any numbered paragraphs (21) - (40) above, said at least one polypropylene homopolymer base resin is suitably under the trade name DAPLOY WB140 (commercially available from Polyaris Corporation).

In any numbered paragraphs (21) - (40) above, said at least one polypropylene homopolymer secondary resin is suitably a crystalline polypropylene homopolymer available as F020HC from Brasco Corporation.

In any numbered paragraphs (21)-(40) above, the at least one nucleating agent is talc (eg, Heritage Plastics HT4HP talc) and HYDROCEROL ^™ CF-40E (commercially available from Clariant Corporation). The physical nucleating agent is suitably talc (eg Heritage Plastics HT4HP talc or MillikenHPR-803i) and the chemical nucleating agent is suitably HYDROCEROL ^™ CF-40E (commercially available from Clariant).

In any numbered paragraphs (21)-(40) above, the at least one slip agent is suitably Ampacet 102823 processing aid PEMBLLDPE.

In any numbered paragraph (21)-(40) above, the colorant is suitably 11933-19 Titanium oxide colorant or Ampacet blue-white colorant.

In a specific embodiment, the formulation of the insulating cellular non-aromatic polymer material is as follows:

86.77wt% DAPLOYWB140 (available from Polyaris);

10 wt% crystalline polypropylene homopolymer available as F020HC from Blasco Corporation

0.13 wt% HYDROCEROL ^™ CF-40E, available from Clariant;

0.6 wt% Heritage Plastics HT4HP talc;

2wt% Ampacet 102823 processing aid PEMBLLDPE; and

0.5wt% Ampacet blue-white colorant

According to another aspect of the present invention, there is provided a method for preparing an insulating material, the method comprising the steps of:

a) mixing the formulations of any of the numbered paragraphs (1)-(40),

b) heating the mixed formulation to a molten state;

c) adding at least one physical blowing agent to said molten, mixed formulation, and

d) Extruding the formulation as an extrudate.

In embodiments, the physical blowing agent is carbon dioxide, which is added to the molten, mixed formulation in step c) at a mass flow rate of 0.5-11 lbs/hr. Suitably, the physical blowing agent is carbon dioxide, which is added to the molten, mixed formulation in step c) at a mass flow rate of 2-11 lbs/hr. More suitably, the physical blowing agent is carbon dioxide, which is added to the molten, mixed formulation in step c) at a mass flow rate of 3-11 lbs/hr. Even more suitably, the physical blowing agent is carbon dioxide, which is added to the molten, mixed formulation in step c) at a mass flow rate of 8-11 lbs/hr. Even suitably, said physical blowing agent is carbon dioxide, which is added to the molten, mixed formulation in step c) at a mass flow rate of 8.5-10.5 lbs/hr. Most suitably, the physical blowing agent is carbon dioxide, which is added to the molten, mixed formulation in step c) at a mass flow rate of 9-10.5 lbs/hr.

According to another aspect of the invention there is provided a product obtainable, obtained or directly obtained by a method as defined herein.

The following numbered entries include contemplated and non-limiting examples:

Item 1. A polymer formulation comprising

about 50–99.9 wt% base resin,

up to about 10% by weight slip agent,

up to about 10% by weight of colorants,

up to about 10% by weight of chemical blowing agents, and

About 0.5-10 wt% nucleating agent.

Item 2. A polymeric material comprising

A polymer formulation comprising about 50 - 99.9 wt% base resin, up to about 10 wt% slip agent, up to about 10 wt% colorant, up to about 10 wt% chemical blowing agent, and about 0.5–10 wt% nucleating agent, and

wherein said polymeric material is cellular and non-aromatic.

Item 3. An insulating container comprising

A polymer material made from a polymer formulation comprising about 50 - 99.9 wt% base resin, up to about 10 wt% slip agent, up to about 10 wt% colorant, up to about 10wt% chemical blowing agent, and about 0.5–10wt% nucleating agent,

wherein the insulating container has an average wall thickness of about 1.4 mm to about 1.8 mm, and

The polymeric material has an average density of about 0.16 g/cm ³ to about 0.19 g/cm ³ .

Item 4. A method for preparing an insulating material, the method comprising

a) Mixed polymer formulations comprising about 50-99.9 wt% of base resin, up to about 10 wt% of slip agent, up to about 10 wt% of colorant, up to about 10 wt% of a chemical blowing agent, and about 0.5–10 wt% of a nucleating agent,

b) heating the mixed formulation to a molten state,

c) adding at least one physical blowing agent to said molten, mixed formulation, and

d) Extruding the formulation as an extrudate.

Item 5. A method of forming an insulating polymeric material, the method comprising

a) Blending

i) a high melt strength polypropylene base resin with long chain branching,

ii) a second polymer comprising a polypropylene copolymer, a polypropylene homopolymer, polyethylene, or a mixture thereof, and

iii) at least one cell nucleating agent to form the resin mixture,

b) heating said resin mixture,

c) adding at least one blowing agent to the resin mixture, and

d) extruding the resin mixture so as to form a structure having cells formed therein.

Item 6. A polymer formulation comprising

a) about 96% or 97% by weight of a base resin, wherein the base resin comprises about 10% by weight of a secondary base resin;

b) about 2% by weight of slip agent;

c) about 0.5 wt% colorant;

d) about 0.1 wt% chemical blowing agent; and

e) about 0.5% nucleating agent.

Item 7. The polymer formulation of any preceding item, wherein the base resin is about 50 to 85 wt%.

Item 8. The polymer formulation of any preceding item, wherein the base resin is about 95 to 98 wt%.

Item 9. The polymer formulation of any preceding item, wherein the base resin is about 96 wt%.

Item 10. The polymer formulation of any preceding item, wherein the base resin is about 97 wt%.

Item 11. The polymer formulation of any preceding item, wherein the base resin comprises a secondary base resin.

Item 12. The polymer formulation of any preceding item, wherein the secondary base resin is up to about 50 wt%.

Item 13. The polymer formulation of any preceding item, wherein the secondary base resin is up to about 10 wt%.

Item 14. The polymer formulation of any preceding Item, wherein the secondary base resin comprises polyethylene.

Item 15. The polymer formulation of any preceding item, wherein the polyethylene is selected from the group consisting of low density polyethylene, linear low density polyethylene, high density polyethylene Ethylene, ethylene-vinyl acetate copolymers, ethylene-ethyl acrylate copolymers, ethylene-acrylic acid copolymers, polymethylmethacrylate mixtures of at least two of the foregoing, and combinations thereof.

Item 16. The polymer formulation of any preceding Item, wherein the minor base resin is about 10 wt%.

Item 17. The polymer formulation of any preceding item, wherein the secondary polypropylene resin is selected from the group consisting of crystalline polypropylene homopolymer, impact polymer Propylene copolymers, and mixtures thereof.

Item 18. The polymer formulation of any preceding item, wherein the crystalline polypropylene homopolymer has more than 51% crystalline phase at a cooling rate of 10°C/min.

Item 19. The polymer formulation of any preceding Item, wherein the slip agent is up to about 5 wt%.

Item 20. The polymer formulation of any preceding Item, wherein the slip agent is about 1 to 3 wt%.

Item 21. The polymer formulation of any preceding Item, wherein the slip agent is about 2 wt%.

Item 22. The polymer formulation of any preceding item, wherein the colorant is up to about 5 wt%.

Item 23. The polymer formulation of any preceding item, wherein the colorant is about 0.5 to 4 wt%.

Item 24. The polymer formulation of any preceding item, wherein the colorant is about 0.5 to 2 wt%.

Item 25. The polymer formulation of any preceding item, wherein the colorant is about 0.5 wt%.

Item 26. The polymer formulation of any preceding item, wherein the colorant is about 1 wt%.

Item 27. The polymer formulation of any preceding item, wherein the nucleating agent is about 0.5 to 5 wt%.

Item 28. The polymer formulation of any preceding item, wherein the nucleating agent is about 0.5 wt%.

Item 29. The polymer formulation of any preceding Item, wherein the chemical blowing agent is about 0.1 to 5 wt%.

Item 30. The polymer formulation of any preceding Item, wherein the chemical blowing agent is about 0.1 to 2 wt%.

Item 31. The polymer formulation of any preceding item, wherein the chemical blowing agent is about 0.1 to 1 wt%.

Item 32. The polymer formulation of any preceding item, wherein the chemical blowing agent is about 0.1 wt%.

Item 33. The polymer formulation of any preceding item, wherein the base resin is a polypropylene resin.

Item 34. The polymer formulation of any preceding Item, wherein the polypropylene resin is a high melt strength polypropylene.

Item 35. The polymer formulation of any preceding item, wherein the base resin is a polypropylene resin having a unimodal molecular weight distribution.

Item 36. The polymer formulation of any preceding item, wherein the base resin has a melt strength of at least 36 according to ISO16790.

Item 37. The polymer formulation of any preceding item, wherein the base resin has a melting temperature of at least 163°C.

Item 38. The polymer formulation of any preceding item, wherein the nucleating agent is selected from the group consisting of a chemical nucleating agent, a physical nucleating agent, or a chemical nucleating agent. A combination of nucleating and physical nucleating agents.

Item 39. The polymer formulation of any preceding item, wherein the chemical nucleating agent is citric acid or a citric acid-based material.

Item 40. The polymer formulation of any preceding item, wherein the physical nucleating agent is selected from the group consisting of talc, CaCO ₃ , mica, kaolin, chitin , aluminosilicate, graphite, cellulose, and mixtures of at least two of the foregoing.

Item 41. The polymer formulation of any preceding item, further comprising a physical blowing agent.

Item 42. The polymer formulation of any preceding item, wherein said physical blowing agent is selected from the group consisting of carbon dioxide, nitrogen, helium, argon, air, Water vapor, pentane, butane, and mixtures thereof.

Item 43. The polymer formulation of any preceding item, wherein the physical blowing agent is selected from the group consisting of hydrofluoroalkanes, hydrofluoroalkenes, haloalkanes, or haloalkanes The refrigerant.

Item 44. The polymer formulation of any preceding item, wherein the hydrofluoroalkane is 1,1,1,2-tetrafluoroethane.

Item 45. The polymer formulation of any preceding item, wherein the hydrofluoroolefin is 1,3,3,3-tetrafluoropropene.

Item 46. The polymer formulation of any preceding item, further comprising a processing aid that enhances the solubility of the physical blowing agent.

Item 47. The polymer formulation of any preceding item, wherein the physical blowing agent is at least one gas introduced as a liquid under pressure into the molten resin.

Item 48. The polymer formulation of any preceding item, wherein the chemical blowing agent is selected from the group consisting of: azodicarbonamide; azobisiso Butyronitrile; Benzenesulfonylhydrazide; 4,4-oxybenzenesulfonylsemicarbazide; p-toluenesulfonylsemicarbazide; barium azodicarboxylate; Nitroterephthalamide; Trihydrazinotriazine; Methane; Ethane; Propane; n-Butane; Isobutane; n-Pentane; Isopentane; Neopentane; Methyl Fluoride; Perfluoromethane; B 1,1-difluoroethane; 1,1,1-trifluoroethane; 1,1,1,2-tetrafluoroethane; pentafluoroethane; perfluoroethane; 2,2- Difluoropropane; 1,1,1-trifluoropropane; perfluoropropane; perfluorobutane; perfluorocyclobutane; methyl chloride; methylene chloride; ethyl chloride; 1,1,1-trichloro Ethane; 1,1-dichloro-1-fluoroethane; 1-chloro-1,1-difluoroethane; 1,1-dichloro-2,2,2-trifluoroethane; 1-chloro -1,2,2,2-Tetrafluoroethane; Trichloromonofluoromethane; Dichlorodifluoromethane; Trichlorotrifluoroethane; Dichlorotetrafluoroethane; Chloroheptafluoropropane; Dichlorohexafluoropropane; Methanol ;Ethanol; n-propanol; isopropanol; sodium bicarbonate; sodium carbonate; ammonium bicarbonate; ammonium carbonate; ammonium nitrite; Formamide; N,N'-Dinitrosopentamethylenetetramine; Azobisisobutyronitrile; Azocyclohexylnitrile; Azodiaminobenzene; Benzenesulfonylhydrazide; Toluenesulfonylhydrazide; p, p'-oxobis(benzenesulfonylhydrazide); diphenylsulfone-3,3'-disulfonylhydrazine; calcium azide; 4,4'-diphenyldisulfonyl azide; - Tosyl azide.

Item 49. The polymer formulation of any preceding item, wherein the slip agent is an amide of a fat or fatty acid, a low molecular weight amide, or a fluoroelastomer.

Item 50. The polymer formulation of any preceding item, wherein the fatty acid amide is a monounsaturated _C18 to _C22 amide.

Item 51. The polymer formulation of any preceding item, wherein the fatty acid amide is erucamide or oleamide.

Item 52. The polymer formulation of any preceding item, wherein the colorant is titanium dioxide.

Item 53. The polymeric material of any preceding item, wherein the base resin is homopolymer polypropylene.

Item 54. The polymeric material of any preceding Item, wherein the polymeric material has an average aspect ratio of cells of from about 1.0 to about 3.0.

Item 55. The polymeric material of any preceding Item, wherein the polymeric material has an average aspect ratio of cells of from about 1.0 to about 2.0.

Item 56. The polymeric material of any preceding Item, wherein the average cell aspect ratio is about 2.0.

Item 57. The polymeric material of any preceding item, wherein the polymeric material has a density of about 0.01 g/ ^cm3 to 0.19 g/ _cm3 .

Item 58. The polymeric material of any preceding item, wherein the polymeric material has a density of about 0.05 g/ ^cm3 to 0.19 g/ _cm3 .

Item 59. The polymeric material of any preceding Item, wherein the polymeric material has a density of about 0.1 g/ ^cm3 to 0.185 g/ _cm3 .

Item 60. The polymeric material of any preceding Item, wherein the polymeric material has a tear resistance in the machine direction of at least about 282 grams-force according to ASTM D1922-93.

Item 61. The polymeric material of any preceding Item, wherein the polymeric material requires at least about 282 gram-force in the machine direction to tear the Material.

Item 62. The polymeric material of any preceding item, wherein the polymeric material structure requires at least about 212 grams in the transverse direction according to the Elmendorf test method as described in ASTM D1922-93 - force to tear the material.

Item 63. The polymeric material of any preceding item, wherein the polymeric material requires a force in the machine direction of about 213 gram-force to about 351 gram-force according to the Elmendorf test method ASTM D1922-93. Force within the force range to tear the material.

Item 64. The polymeric material of any preceding Item, wherein the polymeric material requires, in the transverse direction, between about 143 gram-force and about 281 gram-force according to Elmendorf Test Method ASTM D1922-93. Force within the force range to tear the material.

Item 65. The polymeric material of any preceding Item, said polymeric material having an average thermal conductivity of about 0.05136 W/m-K at 21°C.

Item 66. The polymeric material of any preceding Item, said polymeric material having an average thermal conductivity at 93°C of about 0.06389 W/m-K.

Item 67. The polymeric material of any preceding Item, further comprising a printed laminate film, wherein the polymeric material has an average thermal conductivity of about 0.05321 W/m-K at 21°C.

Item 68. The polymeric material of any preceding Item, further comprising a printed laminate film, wherein the polymeric material has an average thermal conductivity of about 0.06516 W/m-K at 93°C.

Item 69. The insulated container of any preceding item, wherein the insulated container has a temperature of about 49°C to about 63°C after being filled with a liquid of about 93.3°C and placing the lid on the container for 5 minutes. outer wall temperature.

Item 70. The insulated container of any preceding Item, wherein the insulated container has a maximum outer wall temperature less than 5 minutes after being filled with a liquid of about 93.3°C and placing a lid on the container.

Item 71. The insulated container of any preceding Item, wherein said outer wall temperature is less than said maximum outer wall temperature 5 minutes after filling with a liquid of about 93.3°C and placing a lid on said container.

Item 72. The method of any preceding item, wherein said at least one blowing agent is selected from the group consisting of carbon dioxide, nitrogen, helium, argon, air, water Vapor, pentane, butane, hydrofluoroalkanes, hydrofluoroalkenes, haloalkanes, haloalkane refrigerants, and mixtures thereof.

Item 73. The method of any preceding Item, wherein step (d) comprises adding the at least one blowing agent at a mass flow rate of about 9.8 lbs/hr.

Item 74. The method of any preceding Item, wherein a) blending further comprises iv) a slip agent, a colorant, or both a slip agent and a colorant.

Item 75. The method of any preceding Item, wherein the blowing agent is a physical blowing agent.

Item 76. The method of any preceding Item, wherein the physical blowing agent is carbon dioxide.

Item 77. The method of any preceding Item, wherein the structure is a sheet.

Item 78. The method of any preceding Item, further comprising e) cutting said sheet and f) forming a cup.

example

The following examples are set forth for purposes of illustration only. Parts and percentages appearing in such examples are by weight unless otherwise specified. All ASTM, ISO, and other standard test methods cited or referred to in this disclosure are incorporated by reference in their entirety.

Example 1 - Formulation and Extrusion

DAPLOY ^™ WB140 polypropylene homopolymer (commercially available from Polyaris Corporation) was used as the polypropylene base resin. F020HC (polypropylene homopolymer resin) commercially available from Blasco Corporation was used as the secondary resin. These two resins were blended with Hydrocerol ^™ CF-40E ^™ as primary nucleating agent, talc as secondary nucleating agent, _CO2 as blowing agent, slip agent, and titanium dioxide as colorant. The percentage is:

The formulation was added to the extruder hopper. The extruder heats the formulation to form a molten resin mixture. Add to this mixture

1.1lbs/ _hrCO2

0.7lbs/hrR134a.

Carbon dioxide and R134a were injected into the resin blend to expand the resin and reduce the density. The mixture thus formed was extruded through a die into sheets. The slices are then cut and formed into cups.

Example 1 - Test Results

Test results for the material formed according to Example 1 showed that the material had a density of about 0.1902 g/cm ³ and a nominal flake gauge of about 0.089 inches (2.2606 mm).

Microwaveability

Containers produced using this material, filled with 12 oz. of room temperature water, were heated in a FISO Microwave Station (1200 Watt) microwave oven for 2.5 minutes without burning or scorching or other visible effects on the cup. In comparison, a paper cup heated in the same microwave charred or burned in less than 90 seconds.

stiffness

testing method

The samples were at 73°F (22.8°C) and 50% relative humidity. The cup hardness/stiffness test is performed using a horizontal load cell containing a load cell in order to measure the resistance of the cup when exposed to the following test conditions: (a) The test location on the cup is 1/3 of the way down from the edge of the cup ; (b) a test travel distance of 0.25 inches (6.35 mm); and (c) a test travel time of 10 seconds.

Test Results

The stiffness of the materials is shown in Tables 1-2 below when the average wall thickness is about 0.064 inches (1.6256 mm), the average density is about 0.1776 g/ ^cm3 , and the average cup weight is about 9.86 g.

Table 1 - Stiffness test results

Table 2 - Summary of Stiffness Test Results in Table 1

insulation

testing method

Use the following typical industry cup insulation test method:

- Attach (cup outside) surface temperature thermocouples to the cup with glue.

• Attach the thermocouple tape to the cup with cellophane tape such that the thermocouple is in the middle of the cup opposite the seam.

• Heat water or other aqueous liquids to near boiling, for example in a microwave.

• Continuously stir the hot liquid with a bulb thermometer while observing the liquid temperature.

• Record the thermocouple temperature.

• When the liquid reaches 200°F (93.3°C), pour the liquid into the cup nearly full.

• Record the surface temperature for a minimum of 5 minutes.

The material thickness is about 0.089 inches (2.2606 mm). The density is about 0.1902 g/cm ³ .

A cup formed from the formulation described above and having a density of about 0.190 g/cm ³ and a wall thickness of about 0.089 inches was used. Hot liquid at 200°F was placed in the cup.

Test Results

The temperature measured on the outer wall of the cup was about 140.5°F (60.3°C), resulting in a drop of about 59.5°F (33°C). The maximum temperature observed was a peak at about 140.5°F (60.3°C) over a 5 minute period. The lower the temperature, the better the insulating properties of the cup material because the material reduces heat transfer from the liquid to the outside of the cup material.

Fragility

Fragility can be defined as resistance to tearing or perforation that would cause shattering.

testing method

The Elmendorf test method described in ASTM D1922-93 was used. The tear radius was 1.7 inches (43.18 mm).

Test Results

The test results are shown in Tables 3-4 below. A material formed as in an exemplary embodiment of the present disclosure provides superior tear force resistance when compared to EPS.

Table 3 - Test Results

Table 4 - Summary of test results in Table 3

Note that there are no data obtained for expanded polystyrene cross direction tests because expanded polystyrene does not have a material orientation (ie, machine or cross direction) due to the manufacturing method. The range of materials tested for this disclosure (calculated as follows: lower limit = mean - (3 x standard deviation); upper limit = mean + (3 x standard deviation)) is about 213 gram-force to about 351 gram-force in the machine direction force and from about 143 gram-force to about 281 gram-force in the transverse direction. In comparison, the expanded polystyrene material tested ranged from about 103 gram-force to about 121 gram-force.

Perforation resistance

testing method

Determine the force and travel required to pierce the side wall and bottom of the cup. The Instron instrument was used in compression mode set at a travel speed of 10 inches (254 mm) per minute. Use a cup piercing test fixture on an Instron base. This fixture fits the cup over a shape that fits inside the cup, with the top surface perpendicular to the travel of the Instron tester. The one inch diameter hole of the clamp should be set upwards. The moving part of the Instron instrument should be fitted with a 0.300 inch (7.62 mm) diameter punch. In the test fixture, the punch is aligned with the hole. Place the cup over the jig and record the force and travel required to pierce the side wall of the cup. Repeat the sidewall puncture test at three evenly spaced locations, but do not perform the puncture test on the cup seam. Test the bottom of the cup. This should be done in the same manner as the sidewall test, except without the jig. Place the cup upside down on the Instron base only with the perforator down on the center of the bottom of the cup.

Test Results

Results for typical sidewall perforations and bottom perforations are shown in Table 5 below.

Table 5 - Piercing Test Results

Slow Puncture Resistance - Straw

testing method

A material formed as in an exemplary embodiment of the present disclosure provides superior puncture resistance when compared to expanded polystyrene using the Slow Puncture Resistance Test Method as described in ASTM D-3763-86. The test results are shown in Tables 6-9 below.

Test Results

Table 6 - Test materials

Table 7 - Comparison: Expanded Polystyrene

Table 8 - Paper Wrapped Expanded Polystyrene

Table 9 – Summary of Slow Pierce-Straw Test Results in Tables 6-8

Example 2 - Formulation and Extrusion

Use the following preparations:

81.70% BorealisWB140HMS main polypropylene

0.25% AmcoA18035PPRO talc-filled concentrate

2% Ampacet102823 processing aid PEMB linear low density polyethylene slip agent

0.05% Hydrocerol CF-40E chemical blowing agent

1% Colortech11933-19 colorant

15% BraskemF020HC high crystallinity homopolymer polypropylene

Introduce 3.4 lbs/hr of _CO2 into the molten resin.

The density of the formed strips ranges from about 0.155 g/cm ³ to about 0.182 g/cm ³ .

The formulation was added to the extruder hopper. The extruder heats the formulation to form a molten resin mixture. _CO2 is added to this mixture in order to expand the resin and reduce the density. The mixture so formed is extruded into a strip 82 through a die. The strip is then cut and the insulating cup 10 is formed.

Example 2 - Test Results

In an exemplary embodiment, the extruded tube of insulative cellular non-aromatic polymeric material has two surfaces formed under different cooling conditions when the material is extruded. One surface (hereinafter will be referred to as the extruded tube outer surface) is in contact with air and has no physical barriers to limit expansion. The outer surface of the extruded tube surface is cooled by blowing compressed air at a cooling rate equal to or greater than 12°F per second. The surface on the opposite side will be referred to as the inside of the extruded tube. The inside of the extruded tube surface is formed when the extruded tube is drawn in the web or machine direction over a metallic cooling surface of a torpedo mandrel that physically confines the inside of the extruded tube, and is passed through a combination of water and compressed air. Cool at a cooling rate of less than 10°F per second. In an exemplary embodiment, the cooling water temperature is about 135°F (57.22°C). In the exemplary embodiment, the cooling air temperature is about 85°F (29.44°C). Due to different cooling mechanisms, the extruded tube outer surface and the extruded tube inner surface have different surface characteristics. The cooling rate and method are known to affect the crystallization process of polypropylene, thereby changing the morphology (crystal domain size) and topography (surface profile and smoothness) of the polypropylene.

An unexpected feature of an exemplary embodiment of an extruded sheet as described herein is the ability of the sheet to form a substantially smooth, wrinkle-free and wrinkled surface when bent to form a circular object such as a cup. The surface is smooth and wrinkle-free even inside the cup, where compressive forces typically tend to wrinkle the material, especially low density materials with large cell sizes. In an exemplary embodiment, the smoothness of the surface of the extruded sheet of insulative cellular non-aromatic polymeric material, as detected by microscopy, is such that when the sheet is subjected to stretching and Under compressive force, the depth of naturally occurring indentations (folds or creases) in the exterior and interior of the cup surface can be less than about 100 microns. In an exemplary embodiment, the smoothness may be less than about 50 microns. In an exemplary embodiment, the smoothness may be about 5 microns or less. At depths of about 10 microns and less, tiny wrinkles on the cup surface are generally invisible to the naked eye.

In one exemplary embodiment, an insulative cup formed from a sheet comprising a skin and a strip of insulative cellular non-aromatic polymeric material has typical creases (deep creases) approximately 200 microns deep extending from the top of the cup to the bottom of the cup. ). In one exemplary embodiment, an insulative cup formed from a sheet comprising only strips of insulative cellular non-aromatic polymeric material (no skin) has typical wrinkles extending from the top of the cup to the bottom of the cup about 200 microns deep . Such wrinkles are typically formed having a depth of from about 100 microns to about 500 microns when the inside of the extruded tube faces the inside of the cup in compression mode. Wrinkles and deep wrinkles can present unsatisfactory surface quality issues, making the final cup unusable or undesirable. Wrinkles may be formed where the sheet includes skins or does not include skins.

In an exemplary embodiment, the insulative cellular non-aromatic polymeric material may be extruded in the form of a ribbon. However, the microscopic images showed the presence of two distinct layers within the extruded ribbon, namely, a matte outer layer of the extruded tube and a glossy inner layer of the extruded tube. The difference between the two layers is surface reflection due to differences in domain size. If a black marker is used to color the surface examined by the microscope, the reflection is eliminated and the difference between the two surfaces can be minimal or undetectable.

In an exemplary embodiment, sample strips are prepared without any skin layer. Use a black marker to eliminate any differences in reflection between layers. The images show that the cell size and cell distribution are the same throughout the thickness of the strip. Wrinkles approximately 200 microns deep are seen as folds within the surface when cell walls collapse under compressive force.

Differential scanning calorimetry analysis performed on a TA Instruments DSC2910 in a nitrogen atmosphere showed that as the cooling rate increased, the crystallization temperature and crystallinity of the polymer matrix material of the ribbons decreased, as shown in Table 10 below.

Table 10

Differential scanning calorimetry data show the dependence of crystallization and subsequent reheating melting temperature and percent crystallinity on cooling rate during crystallization. Exemplary embodiments of the strip of insulative cellular non-aromatic polymeric material may have a melting temperature between about 160°C (320°F) and about 172°C (341.6°F), a melting temperature between about 108°C (226.4 °F) and about 135°C (275°F) and a percent crystallinity between about 42% and about 62%.

In an exemplary embodiment, the extruded sheet has a melting temperature of about 162°C (323.6°F), a melting temperature of about 131°C (267.8°F), as determined by differential scanning calorimetry at a heating and cooling rate of 10°C per minute. °F) and a crystallinity of about 46%.

It has been unexpectedly found that the extruded tube outer surface advantageously functions in compression mode without appreciable wrinkling, and thus a cup (or other structure) may advantageously be made with the extruded tube outer surface facing the interior of the insulating cup become. The difference in the resistance of the extruded tube inner layer and the extruded tube outer layer to compressive force can be attributed to the difference in layer morphology, since they crystallize at different cooling rates.

In an exemplary embodiment where extruded sheets are formed, the inner surface of the extruded tube may be cooled by a combination of water cooling and compressed air. The extruded tube outer surface can be cooled by compressed air by using a torpedo with circulating water and air outlets. Faster cooling rates can result in the formation of smaller sized crystals. Typically, the faster the cooling rate, the greater the relative amount of smaller crystals formed. Exemplary extruded sheets of insulating cellular non-aromatic polymeric material were subjected to X-ray diffraction analysis on a Panalytical X'pert MPDPro diffractometer using Cu radiation at 45KV/40mA. It was confirmed that the outer surface of the extruded tube had a domain size of about 99 angstroms, while the inner surface of the extruded tube had a domain size of about 114 angstroms. In an exemplary embodiment, the extruded strip of insulative cellular non-aromatic polymeric material may have a crystal domain size below about 200 Angstroms. In an exemplary embodiment, the extruded strip of insulative cellular non-aromatic polymeric material may have a crystal domain size preferably below about 115 Angstroms. In an exemplary embodiment, the extruded strip of insulative cellular non-aromatic polymeric material may have a crystal domain size below about 100 Angstroms.

stiffness

testing method

The test method was the same as described in Example 1 for the stiffness test.

Test Results

Stiffness test results are shown in Table 11 below.

Table 11

insulation

Test Method - Wall Temperature

An insulative cup formed from the formulation described above having a density of about 0.18 g/cm ³ and a wall thickness of about 0.074 inches (1.8796 mm) was used. Hot liquid at 200°F (93.3°C) was placed in the cup.

Test Results

The temperature measured on the outside wall of the cup was about 151°F (66.1°C), with a drop of about 49.0°F (27.2°C). The maximum temperature observed was a peak at about 151°F (66.1°C) over a period of five minutes.

Insulation tests are performed in the form of thermal conductivity.

Test Method - Thermal Conductivity

This test measures bulk thermal conductivity (W/mK) measured at ambient temperature as well as 93°C (199.4°F). Use ThermTestTPS2500S thermal constant analyzer instrument, adopt ISO/DIS22007-2.2 test method and use low density/high insulation option. All measurements are made using Insulated TPS Sensor #55010.2521 inch radius (6.403mm radius). Using 0.02 watts of power, the test was performed for 20 seconds. Record data for use points 100-200.

Test Results

The test results are shown in Table 12 below.

Table 12 - Average Thermal Conductivity Results

temperature(°C) Average thermal conductivity (W/m-K) Standard Deviation(W/m-K) twenty one 0.05792 0.00005 93 0.06680 0.00025

Example 3 - Formulation and Extrusion

DAPLOY ^™ WB140 polypropylene homopolymer (commercially available from Polyaris Corporation) was used as the polypropylene base resin. F020HC (polypropylene homopolymer resin) commercially available from Blasco Corporation was used as the secondary resin. These two resins were blended with: Hydrocerol ^TM CF-40E ^TM as chemical blowing agent, talc as nucleating agent, _CO2 as physical blowing agent, slip agent, and Blue-white as colorant. The colorant can be added to the base resin or to the secondary resin and can be done before mixing the two resins. The percentage is:

The density of the formed strips ranges from about 0.140 g/cm ³ to about 0.180 g/cm ³ .

The formulation was added to the extruder hopper. The extruder heats the formulation to form a molten resin mixture. _CO2 is added to this mixture in order to expand the resin and reduce the density. The mixture thus formed is extruded through a die into ribbons. The strip is then cut and an insulating cup is formed.

Carbon dioxide is injected into the resin blend to expand the resin and reduce the density. The mixture thus formed was extruded through a die into sheets. The slices are then cut and formed into cups. Example 3 - Test Results

Test results for the material formed according to Example 3 showed that the material had a density of about 0.1615 g/cm ³ and a nominal flake gauge of about 0.066 inches (1.6764 mm).

Microwaveability

Containers produced using this material were filled with 12 ounces of room temperature water and heated in a FISO ^™ MicrowaveStation (1200 Watt) microwave oven for 2.5 minutes without burning or scorching or other visible effects on the container. In comparison, a paper cup heated in the same microwave charred or burned in less than 90 seconds. In comparison, polyethylene terephthalate (PTFE) foam cups heated in the same microwave showed heavy deformation with visible effects after 2.5 minutes.

stiffness

testing method

The cup samples were at 72°F (22.2°C) and 50% relative humidity. The cup hardness/stiffness test is performed using a horizontal load cell containing a load cell in order to measure the resistance of the cup when exposed to the following test conditions: (a) The test location on the cup is 1/3 of the way down from the edge of the cup ; (b) a test travel distance of 0.25 inches (6.35 mm); and (c) a test travel time of 10 seconds.

Test Results

The stiffness of the materials is shown in Tables 13-14 below when the average wall thickness is about 0.066 inches (1.7018), the average density is about 0.1615 g/ ^cm3 , and the average cup weight is about 11.5 g.

Table 13 - Stiffness test results

Table 14 - Summary of Stiffness Test Results in Table 13

insulation

Thermal Test Method

For temperature measurements use the following typical industry cup insulation test method:

1. Attach the (cup outside) surface temperature thermocouple to the cup with glue.

2. Attach the thermocouple tape to the cup with cellophane tape such that the thermocouple is in the middle of the cup opposite the seam.

3. Heat water or other aqueous liquids to near boiling, for example in a microwave.

4. Continuously stir the hot liquid with a bulb thermometer while observing the liquid temperature.

5. Record the thermocouple temperature.

6. When the liquid reaches 200°F (93.3°C), pour the liquid into the cup nearly full.

7. Put the lid on the cup.

8. Record the surface temperature for a minimum of 5 minutes.

The density and thickness of the material are measured at the test points once the test is complete. The density is about 0.1615 g/cm ³ . The material thickness is about 0.066 inches (1.6764 mm). The average cup weight is about 11.5g.

Test Results

Hot liquid at about 200°F (93.3°C) was placed in the cup for about 5 minutes. The liquid was able to maintain a temperature of about 192°F (88.9°C) after 5 minutes. The temperature of the water inside the cups is shown in Table 15 below.

Table 15 - Summary of water temperature inside the cup

Five minutes after the introduction of the hot liquid, the temperature measured on the outer surface wall of the cup was about 120.8°F (49.3°C), resulting in a difference of about 71.2°F (39.6°C) compared to the internal water temperature. The maximum temperature observed was a peak at about 135.5°F (57.5°C) over a period of five minutes. The lower the surface temperature and the higher the internal water temperature, the better the insulating properties of the cup material because the material minimizes heat transfer between the liquid and the outside of the cup material. Cup surface temperature and water temperature data are shown in Figures 11-12 for a density of about 0.1615 g/ ^cm3 , a wall thickness of about 0.066 inches, and a cup weight of about 11.5 g.

cold test method

For temperature measurements use the following typical industry cup insulation test method:

1. Freeze an ice jar with water overnight

2. Attach the (cup outside) surface temperature thermocouple to the cup with glue.

3. Attach the thermocouple tape to the cup with cellophane tape so that the thermocouple is in the middle of the cup opposite the seam.

4. Remove overnight chilled ice jar with water

5. Observe the liquid temperature with a bulb thermometer

6. Record the thermocouple temperature.

7. Pour the chilled liquid (32.5°F) into the cup almost full.

8. Place the lid on the cup.

9. Record the surface temperature for a minimum of 10 minutes.

The density and thickness of the material are measured at the test points once the test is complete. The density is about 0.1615 g/cm ³ . The material thickness is about 0.066 inches (1.6764 mm). The average cup weight is about 11.5g.

Test Results

The cold liquid at about 32.5°F (0.28°C) was placed in the cup for about 10 minutes. The liquid was able to maintain a temperature of about 33.7°F (0.94°C) after 10 minutes. The temperature of the water inside the cups is shown in Table 16 below.

Table 16 - Summary of water temperature inside the cup

Ten minutes after the introduction of the cold liquid, the temperature measured on the outer surface wall of the cup was about 51.9°F (11.06°C), resulting in a difference of about 18.2°F (10.12°C) compared to the internal water temperature. A minimum temperature drop was observed to nadir at about 50.5°F (10.28°C) over a ten minute period. The higher the surface temperature and the lower the internal water temperature, the better the insulating properties of the cup material because the material minimizes heat transfer between the outside of the cup material and the liquid. The cup surface temperature and water temperature data are shown below in Figures 13-14 for a density of about 0.1615 g/ ^cm3 , a wall thickness of about 0.066 inches, and a cup weight of about 11.5 g.

Example 4 - Method for Formation of Trays

Sheets of materials as disclosed herein can be made by single or double lamination processes.

The sheet was laminated with approximately 0.002 inch thick cast polypropylene film (can be done on one or both sides), set up in an off-line thermoforming process (but an in-line process is also possible).

Load the Rollstock on the machine. The coils are fed into an oven where the material is heated to provide the proper forming conditions. Matching (convex-concave) metal tools form the heated sheet to the desired dimensions. Matching metal tools are used to form the core and cavity side delimitation of the part. Process variables such as vacuum and form air may or may not be used. The flakes thus formed are trimmed. Trimming can be done in-mold, or post-trimming. The pallet in this Example 4 was post-trimmed with the formed article remaining in the web as it continued to the edge trimmer where it was trimmed from the web. Figure 15 shows a tray formed in accordance with the present disclosure.

Fragility

Fragility can be defined as resistance to tearing or perforation that would cause shattering.

testing method

The Elmendorf test method described in ASTM D1922-93 was used. The tear radius was 1.7 inches (43.18mm).

Test Results

The test results are shown in Tables 17-18 below. When compared to EPS, a material formed as in one exemplary embodiment of the present disclosure provides superior tear force resistance in both foam side top and foam side bottom orientations.

Table 17 - Test Results

Table 18 - Summary of test results

Note that there are no data obtained for expanded polystyrene cross direction tests because expanded polystyrene does not have a material orientation (ie, machine or cross direction) due to the manufacturing method. The ply structure formed as in one exemplary embodiment of the present disclosure provides unexpected tear resistance to the material. For the top foam orientation, the range for the materials tested (calculated as: lower limit = mean - (3 x standard deviation); upper limit = mean + (3 x standard deviation)) is about 191 grams-force in the machine direction to about 354 gram-force and in the transverse direction from about 129 gram-force to about 308 gram-force. For the top foam orientation, the materials tested ranged from about 251 gram-force to about 345 gram-force in the machine direction and from about 138 gram-force to about 305 gram-force in the transverse direction. In comparison, the expanded polystyrene material tested ranged from about 103 gram-force to about 121 gram-force.

Perforation resistance

testing method

Determine the force and travel required to pierce the side wall and bottom of the cup. The Instron instrument was used in compression mode set at a travel speed of 10 inches (254 mm) per minute. Use a cup piercing test fixture on an Instron base. This fixture fits the cup over a shape that fits inside the cup, with the top surface perpendicular to the travel of the Instron tester. The one inch diameter hole of the clamp should be set upwards. The moving part of the Instron instrument should be fitted with a 0.300 inch (7.62 mm) diameter punch. In the test fixture, the punch is aligned with the hole. Place the cup over the jig and record the force and travel required to pierce the side wall of the cup. Repeat the sidewall puncture test at three evenly spaced locations, but do not perform the puncture test on the cup seam. Test the bottom of the cup. This should be done in the same manner as the sidewall test, except without the jig. Place the cup upside down on the Instron base only with the perforator down on the center of the bottom of the cup.

Test Results

Results for typical sidewall perforations and bottom perforations are shown in Table 19 below.

Table 19 - Piercing Test Results

Slow Puncture Resistance - Straw

testing method

Using the slow puncture resistance test method as described in ASTM D-3763-86, when compared to expanded polystyrene, the material as formed provides superior performance on both side-top and side-bottom. Piercing resistance. The material as formed has unexpectedly slow puncture resistance due to lamination and orientation of the film. The test results are shown in Tables 20-23 below.

Test Results

Table 20 - Materials Tested Foam Side-Top

Materials tested Foam side-bottom

Table 21 - Comparison: Expanded Polystyrene

Table 22 - Paper Wrapped Expanded Polystyrene

Table 23 – Summary of Slow Pierce-Straw Test Results in Tables 20-22

DartDrop

testing method

The material as formed provides superior puncture resistance as described in ASTM D-1709. Dart Impact Value is a measure of the mass required to produce 50% failure when a dart is dropped from 26 inches. The test results are shown in Table 24 below.

Test Results

Table 24 - Falling Darts (26 inches)

Example 5 - Forming

Materials were fabricated according to the method described in Example 3 above. Samples were labeled Sample A and Sample B for identification.

Sample A is the material itself.

Sample B is a material that has been laminated with a printed film as follows.

The film consists of three layers: a core layer and two skin layers. The core layer is polypropylene based and constitutes 90% of the film. The two skin layers are a blend of polypropylene and polyethylene and each skin layer constitutes 5% of the film. The films were printed in a flexographic system using printing inks that were solvent based for reverse printing.

The film was laminated to the sheet formed in Example 1 as follows. A 0.7 μm thick film was coated with solvent free adhesive at 1.5 lbs per ream. The adhesive consisted of 2 parts urethane and 1 part isocyanato-based epoxy adhesive. The coated film was clamped to the material formed in Example 1. Lamination can be done by different methods such as, but not limited to, flexographic printing and take-up roll systems.

Example 5 - Test Results

cell size

The material formed in Example 5 had an average cell size in the cross direction (CD) of 18.45 mil height by 8.28 mil width. The aspect ratio is 2.23. The average cell size in the machine direction (DD) is 19.54 mils height by 8.53 mils width. The aspect ratio is 2.53.

Thermal conductivity

The bulk thermal conductivity (W/m·K) of the two samples was measured at 21°C and 93°C. The ThermTest TPS2500S Thermal Constant Analyzer (available from ThermTest, Inc.) was the instrument of choice for all bulk thermal conductivity measurements. The TPS2500S analyzer meets the ISO standard ISO/DIS22007-2.2.

For Sample A there are four stock flakes included and for Sample B there are two stock flakes included. Sample A has a nominal thickness of 1.8mm and Sample B has a nominal thickness of 2.0mm. In short, the basic principle of the TPS analyzer system is that the sample surrounds the TPS sensor in all directions and the heat formed in the sensor diffuses freely in all directions. The solution of the heat conduction equation assumes that the sensor is in an infinite medium, so the measurement and analysis of the data must take into account the limitations imposed by the sample boundaries.

Each foam sample was layered to increase the available sample thickness and allow for optimal measurement parameters. For Sample A, 12 coupons of approximately 50 square millimeters were cut and 6 layers were used on each side of the TPS sensor. For Sample B, cut 8 approximately 50 mm square coupons and use 4 layers on each side of the TPS sensor.

To measure the stratified foam samples, a low density/high insulation analysis method was used. This method is useful for determining the bulk thermal conductivity of low density/high insulating materials on the order of 0.1 W/m·K (and lower). The smaller TPS sensor is calibrated to correct for heat loss through the connecting wires, and thus the bulk thermal conductivity results are accurate and consistent with the TPS system regardless of the TPS used. For the calibration of the TPS sensor used for the measurements, the characterized extruded polystyrene samples were measured with a TPS sensor #5501 (6.403 mm radius). The sensor specific calibration factor was found to be 0.000198. The experimental setup was placed in the chamber of a Cascade ^™ TEK Model TFO-1 forced-air laboratory oven. Chamber temperature was monitored with an onboard Watlow "ramp & soak controller". A 60 minute relaxation period was implemented to ensure that the foam samples were isothermal. Check the interface temperature to confirm isothermal stability by running a preliminary TPS measurement. Multiple measurements were performed on each sample at each temperature to confirm reproducibility.

Measurements were made using the TPS standard analysis method and the low density/high insulation option. use has Insulated TPS sensor #5501 (6.403mm radius). It was determined that a 40 second test and a power of 0.02 watts were the optimum test parameters.

The test results are shown in Tables 25 and 26 below.

Table 25

Sample A - Bulk Thermal Conductivity Results

Table 26

Sample B - Bulk Thermal Conductivity Results

Example 6 - Formulation and Extrusion

DAPLOY ^™ WB140HMS polypropylene homopolymer (commercially available from Polyaris Corporation) was used as the polypropylene base resin. PP527K, a polypropylene homopolymer resin (commercially available from Sabic) was used as the secondary resin. These two resins were blended with Hydrocerol ^™ CF-40E ^™ (commercially available from Clariant) as primary nucleating agent, talc as secondary nucleating agent, _CO as blowing agent, Ampacet ^™ 102823LLDPE ( Linear Low Density Polyethylene) (purchased from An Matching Company) as a slip agent, and titanium dioxide as a colorant. The colorant can be added to the base resin or to the secondary resin and can be done before mixing the two resins. The percentage is:

The formulation was added to the extruder hopper. The extruder heats the formulation to form a molten resin mixture. Add to this mixture

2.2lbs/ _hrCO2

Carbon dioxide is injected into the resin blend to expand the resin and reduce the density. The mixture thus formed was extruded through a die into sheets. The slices are then cut and formed into cups. Example 6 - Test Results

Test results for the material formed according to Example 6 showed that the material had a density of about 0.164 g/cm ³ and a nominal flake gauge of about 0.067 inches (1.7018 mm).

stiffness

testing method

The samples were at 73°F (22.8°C) and 50% relative humidity. The cup hardness/stiffness test was performed using a horizontal dynamometer with a load cell in order to measure the resistance of the cup when exposed to the following test conditions: (a) the test location on the cup is 1/3 of the way down from the rim; (b ) a test travel distance of 0.25 inches (6.35 mm); and (c) a test travel time of 10 seconds.

Test Results

The stiffness of the materials is shown in Tables 27-28 below when the average wall thickness is about 0.067 inches (1.7018 mm), the average density is about 0.164 g/ ^cm3 , and the average cup weight is about 10.6 g.

Table 27A - Stiffness Test Results

Form 27B

Form 27C

Form 27D

Form 27E

Table 28 - Summary of Stiffness Test Results for Tables 27A-E

insulation

testing method

Use the following typical industry cup insulation test method:

- Attach (cup outside) surface temperature thermocouples to the cup with glue.

• Attach thermocouple tape to the cup with cellophane tape such that the thermocouple is in the middle of the cup opposite the seam.

• Heat water or other aqueous liquids to near boiling, for example in a microwave.

• Continuously stir the hot liquid with a bulb thermometer while observing the liquid temperature.

• Record the thermocouple temperature.

• When the liquid reaches 200°F (93.3°C), pour the liquid into the cup nearly full.

• Put the lid on the cup.

• Record the surface temperature for a minimum of 5 minutes.

Test Results

Using cups formed from the formulation described above, the cups had an average wall thickness of about 0.067 inches (1.7018 mm), an average density of about 0.164 g/cm ³ , and an average cup weight of about 10.6 g. Hot liquid at 200°F (93.3°C) was placed in the cup.

Test Results

After 5 minutes, the temperature measured on the outer wall of the cup was about 139.2°F (59.5°C), resulting in a drop of about 60.8°F (33.8°C), as seen in FIG. 16 . The maximum temperature was observed as a peak at about 143.2°F (61.8°C) over a period of five minutes, as seen in FIG. 16 . The lower the temperature, the better the insulating properties of the cup material because the material reduces heat transfer from the liquid to the outside of the cup material.

Example 7 - Formulation and Extrusion

DAPLOY ^™ WB140HMS polypropylene homopolymer (commercially available from Polyaris Corporation) was used as the polypropylene base resin. PP527K, a polypropylene homopolymer resin (commercially available from Sabic) was used as the secondary resin. These two resins were blended with Hydrocerol ^™ CF-40E ^™ (commercially available from Clariant) as primary nucleating agent, talc as secondary nucleating agent, _CO as blowing agent, Ampacet ^™ 102823LLDPE ( Linear Low Density Polyethylene) (purchased from An Matching Company) as a slip agent, and titanium dioxide as a colorant. The colorant can be added to the base resin or to the secondary resin and can be done before mixing the two resins. The percentage is:

The formulation was added to the extruder hopper. The extruder heats the formulation to form a molten resin mixture. Add to this mixture

2.2lbs/ _hrCO2

Carbon dioxide is injected into the resin blend to expand the resin and reduce the density. The mixture thus formed was extruded through a die into sheets. The slices are then cut and formed into cups. Example 7 - Test Results

Test results for the material formed according to Example 7 showed that the material had a density of about 0.166 g/cm ³ and a nominal flake gauge of about 0.067 inches (1.7018 mm).

stiffness

testing method

The samples were at 73°F (22.8°C) and 50% relative humidity. The cup hardness/stiffness test was performed using a horizontal dynamometer with a load cell in order to measure the resistance of the cup when exposed to the following test conditions: (a) the test location on the cup is 1/3 of the way down from the rim; (b ) a test travel distance of 0.25 inches (6.35 mm); and (c) a test travel time of 10 seconds.

Test Results

The stiffness of the materials is shown in Tables 29-30 below when the average wall thickness is about 0.067 inches (1.7018 mm), the average density is about 0.166 g/ ^cm3 , and the average cup weight is about 10.6 g.

Table 29A - Stiffness Test Results

Form 29B

Form 29C

Table 30 - Summary of Stiffness Test Results for Tables 29A-C

insulation

testing method

Use the following typical industry cup insulation test method:

- Attach (cup outside) surface temperature thermocouples to the cup with glue.

• Attach thermocouple tape to the cup with cellophane tape such that the thermocouple is in the middle of the cup opposite the seam.

• Heat water or other aqueous liquids to near boiling, for example in a microwave.

• Continuously stir the hot liquid with a bulb thermometer while observing the liquid temperature.

• Record the thermocouple temperature.

• When the liquid reaches 200°F (93.3°C), pour the liquid into the cup nearly full.

• Put the lid on the cup.

• Record the surface temperature for a minimum of 5 minutes.

Test Results

Using cups formed from the formulation described above, the cups had an average wall thickness of about 0.067 inches (1.7018 mm), an average density of about 0.166 g/cm ³ , and an average cup weight of about 10.6 g. Hot liquid at 200°F (93.3°C) was placed in the cup.

After 5 minutes, the temperature measured on the outer wall of the cup was about 144.3°F (62.4°C), resulting in a drop of about 55.7°F (30.9°C), as seen in FIG. 17 . The maximum temperature was observed as a peak at about 148.1°F (64.5°C) over a period of five minutes, as seen in FIG. 17 . The lower the temperature, the better the insulating properties of the cup material because the material reduces heat transfer from the liquid to the outside of the cup material.

Example 8 - Formulation and Extrusion

DAPLOY ^™ WB140HMS polypropylene homopolymer (commercially available from Polyaris Corporation) was used as the polypropylene base resin. F020HC polypropylene homopolymer resin (commercially available from Brasco Corporation) was used as the secondary resin. These two resins were blended with Hydrocerol ^™ CF-40E ^™ as primary nucleating agent, HPR-803i fiber (commercially available from Milliken) as secondary nucleating agent, _CO as hair Foaming agent, Ampacet ^™ 102823LLDPE as slip agent, and titanium dioxide as colorant. The colorant can be added to the base resin or to the secondary resin and can be done before mixing the two resins. The percentage is:

The formulation was added to the extruder hopper. The extruder heats the formulation to form a molten resin mixture. Add to this mixture

2.2lbs/ _hrCO2

Carbon dioxide is injected into the resin blend to expand the resin and reduce the density. The mixture thus formed was extruded through a die into sheets. The slices are then cut and formed into cups. Example 8 - Test Results

Test results for the material formed according to Example 8 showed that the material had a density of about 0.166 g/cm ³ and a nominal flake gauge of about 0.067 inches (1.7018 mm).

stiffness

testing method

The samples were at 73°F (22.8°C) and 50% relative humidity. The cup hardness/stiffness test was performed using a horizontal dynamometer with a load cell in order to measure the resistance of the cup when exposed to the following test conditions: (a) the test location on the cup is 1/3 of the way down from the rim; (b ) a test travel distance of 0.25 inches (6.35 mm); and (c) a test travel time of 10 seconds.

Test Results

The stiffness of the materials is shown in Tables 31-32 below when the average wall thickness is about 0.067 inches (1.7018 mm), the average density is about 0.166 g/ ^cm3 , and the average cup weight is about 10.6 g.

Table 31A - Stiffness Test Results

Form 31B

Form 31C

Form 31D

Form 31E

Table 32 - Summary of Stiffness Test Results for Tables 31A-E

insulation

testing method

Use the following typical industry cup insulation test method:

- Attach (cup outside) surface temperature thermocouples to the cup with glue.

• Attach the thermocouple tape to the cup with cellophane tape such that the thermocouple is in the middle of the cup opposite the seam.

• Heat water or other aqueous liquids to near boiling, for example in a microwave.

• Continuously stir the hot liquid with a bulb thermometer while observing the liquid temperature.

• Record the thermocouple temperature.

• When the liquid reaches 200°F (93.3°C), pour the liquid into the cup nearly full.

• Put the lid on the cup.

• Record the surface temperature for a minimum of 5 minutes.

Using cups formed from the formulation described above, the cups had an average wall thickness of about 0.067 inches (1.7018 mm), an average density of about 0.166 g/cm ³ , and an average cup weight of about 10.6 g. Hot liquid at 200°F (93.3°C) was placed in the cup.

Test Results

After 5 minutes, the temperature measured on the outer wall of the cup was about 144.8°F (62.7°C), resulting in a drop of about 55.2°F (30.6°C), as seen in FIG. 18 . The maximum temperature was observed as a peak at about 149.1°F (65.1°C) over a period of five minutes, as seen in FIG. 18 . The lower the temperature, the better the insulating properties of the cup material because the material reduces heat transfer from the liquid to the outside of the cup material.

Example 9 - Formulation and Extrusion

Example 9 utilized the same formulation and extrusion method as described in Example 3 above.

Example 9 - Test Results

Test results for the material formed according to Example 9 showed that the material had a density of about 0.160 g/cm ³ and a nominal flake gauge of about 0.058 inches (1.473 mm).

stiffness

testing method

The samples were at 73°F (22.8°C) and 50% relative humidity. The cup hardness/stiffness test was performed using a horizontal dynamometer with a load cell in order to measure the resistance of the cup when exposed to the following test conditions: (a) the test location on the cup is 1/3 of the way down from the rim; (b ) a test travel distance of 0.25 inches (6.35 mm); and (c) a test travel time of 10 seconds.

Test Results

The stiffness of the materials is shown in Tables 33-34 below when the average wall thickness is about 0.058 inches (1.473 mm), the average density is about 0.160 g/ ^cm3 , and the average cup weight is about 9.9 g.

Table 33A - Stiffness Test Results

Form 33B

Form 33C

Form 33D

Table 34 - Summary of Stiffness Test Results for Table 33A-E

insulation

testing method

The test method used to test the insulation was the insulation test method as described above in Example 3.

Using cups formed from the formulation described above, the cups had an average wall thickness of about 0.058 inches (1.473 mm), an average density of about 0.160 g/cm ³ , and an average cup weight of about 9.9 g. Hot liquid at 200°F (93.3°C) was placed in the cup.

Test Results

After 5 minutes, the temperature measured on the outer wall of the cup was about 142.1°F (61.2°C), resulting in a drop of about 57.9°F (32.1°C), as seen in FIG. 19 . The maximum temperature was observed as a peak at about 146.0°F (63.3°C) over a period of five minutes, as seen in FIG. 19 . The lower the temperature, the better the insulating properties of the cup material because the material reduces heat transfer from the liquid to the outside of the cup material.

Example 10 - Formulation and Extrusion

Example 10 utilized the same formulation and extrusion method as described in Example 3 above. Example 10 - Test Results

Test results for the material formed according to Example 10 showed that the material had a density of about 0.186 g/cm ³ and a nominal flake gauge of about 0.065 inches (1.651 mm).

stiffness

testing method

The samples were at 73°F (22.8°C) and 50% relative humidity. The cup hardness/stiffness test was performed using a horizontal dynamometer with a load cell in order to measure the resistance of the cup when exposed to the following test conditions: (a) the test location on the cup is 1/3 of the way down from the rim; (b ) a test travel distance of 0.25 inches (6.35 mm); and (c) a test travel time of 10 seconds.

Test Results

The stiffness of the materials is shown in Tables 35-36 below when the average wall thickness is about 0.065 inches (1.651 mm), the average density is about 0.186 g/ ^cm3 , and the average cup weight is about 11.9 g.

Table 35A - Stiffness Test Results

Form 35B

Form 35C

Form 35D

Form 35E

Table 36 - Summary of Stiffness Test Results for Table 35A-E

insulation

testing method

The test method used to test the insulation was the insulation test method as described in Example 3 above.

Test Results

Using cups formed from the formulation described above, the cups had an average wall thickness of about 0.065 inches (1.651 mm), an average density of about 0.186 g/cm ³ , and an average cup weight of about 11.9 g. Hot liquid at 200°F (93.3°C) was placed in the cup.

After 5 minutes, the temperature measured on the outer wall of the cup was about 144.5°F (62.5°C), resulting in a drop of about 55.5°F (30.8°C), as seen in FIG. 20 . The maximum temperature was observed as a peak at about 149.1°F (65.1°C) over a period of five minutes, as seen in FIG. 20 . The lower the temperature, the better the insulating properties of the cup material because the material reduces heat transfer from the liquid to the outside of the cup material.

Example 11 - Formulation and Extrusion

DAPLOYTM WB140 polypropylene homopolymer (commercially available from Polyaris Corporation) was used as the polypropylene base resin. F020HC (polypropylene homopolymer resin) commercially available from Blasco Corporation was used as the secondary resin. These two resins were blended with Hydrocerol ^™ CF-40E ^™ as chemical blowing agent, talc as nucleating agent, _CO2 as physical blowing agent, slip agent, and Ampacet Blue-White as colorant. The colorant can be added to the base resin or to the secondary resin and can be done before mixing the two resins. The percentage is:

The formulation was added to the extruder hopper. The extruder heats the formulation to form a molten resin mixture. _CO2 is added to this mixture in order to expand the resin and reduce the density. The mixture thus formed is extruded through a die into ribbons. The strip is then cut and an insulating cup is formed.

Carbon dioxide is injected into the resin blend to expand the resin and reduce the density. The mixture thus formed was extruded through a die into sheets. The slices are then cut and formed into cups.

Example 12 - Formulation and Extrusion

DAPLOYTM WB140 polypropylene homopolymer (commercially available from Polyaris Corporation) was used as the polypropylene base resin. F020HC (polypropylene homopolymer resin) commercially available from Blasco Corporation was used as the secondary resin. These two resins were blended with: Hydrocerol ^™ CF-40E ^™ as chemical blowing agent (CBA), talc as nucleating agent, _CO2 as physical blowing agent, slip agent, and Ampacet blue-white as Colorant. The colorant can be added to the base resin or to the secondary resin and can be done before mixing the two resins. The percentage is:

The formulation was added to the extruder hopper. The extruder heats the formulation to form a molten resin mixture. _CO2 was added to the respective mixtures in order to expand the resin and reduce the density. The mixture thus formed is extruded through a die into ribbons. The strip is then cut and an insulating cup is formed.

Carbon dioxide is injected into the resin blend to expand the resin and reduce the density. The mixture thus formed is extruded through a die into sheets. The sheet is then cut and formed into cups.

Although only a few exemplary embodiments have been described in detail above, those skilled in the art will readily appreciate that many changes are possible in the exemplary embodiments without materially departing from the novel teachings and advantages. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims.

As used in this specification and the appended claims, the singular forms "a/an" and "the" include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from "about" one particular value, and/or to "about" another particular value. When such a range is stated, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another embodiment. Furthermore, it is to be understood that the endpoints of each of the ranges are both significantly related to, and substantially independent of, the other endpoints.

"Optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

Throughout the description and claims of this specification, the word "comprise" and variations of that word, such as "comprising" and "comprises", mean "including (but not limited to)" and are not intended to exclude, for example, other additives, components, integers or steps. "Exemplary" means "an example" and is not intended to convey an indication of a preferred or ideal embodiment. "For example" is not used in a limiting sense, but for illustrative purposes.

Disclosed are components that can be used to perform the disclosed methods, apparatuses, and systems. These and other components are disclosed herein, and it is to be understood that when combinations, subsets, interactions, groups, etc. References may not be expressly disclosed, but for all methods, apparatus and systems, each is specifically considered and described herein. This applies to all aspects of this application including, but not limited to, steps in the disclosed methods. Thus, if there are a number of additional steps that can be performed, it is understood that each of said additional steps can be performed with any particular embodiment or combination of embodiments of the disclosed method.

It will be apparent to those of ordinary skill in the art that various changes and modifications can be made without departing from the scope or spirit of the present disclosure. Other embodiments will be apparent to those of ordinary skill in the art from consideration of the specification and practice disclosed herein. It is intended that the specification and examples be considered illustrative only.

Furthermore, it should be noted that any publications and documents mentioned herein are incorporated by reference in their entirety.

Claims (78)

1. polymer formulation product, comprise

The base resin of approximately 50 – 99.9wt%,

Be up to the slip agent of about 10wt%,

Be up to the colouring agent of about 10wt%,

Be up to the CBA of about 10wt%, and

The nucleator of approximately 0.5 – 10wt%.

2. polymer formulation product as claimed in claim 1, wherein said base resin is approximately 50 to 85wt%.

3. polymer formulation product as claimed in claim 1, wherein said base resin is approximately 95 to 98wt%.

4. polymer formulation product as claimed in claim 3, wherein said base resin is about 96wt%.

5. polymer formulation product as claimed in claim 3, wherein said base resin is about 97wt%.

6. polymer formulation product as claimed in claim 1, wherein said base resin comprises less important base resin.

7. polymer formulation product as claimed in claim 6, wherein said less important base resin is to be up to about 50wt%.

8. polymer formulation product as claimed in claim 6, wherein said less important base resin is to be up to about 10wt%.

9. polymer formulation product as claimed in claim 6, wherein said less important base resin comprises polyethylene.

10. polymer formulation product as claimed in claim 9, wherein said polyethylene is selected from lower group, and described group by the followingComposition: low density polyethylene (LDPE), LLDPE, high density polyethylene (HDPE), vinyl-vinyl acetate copolymer, ethene-the thirdThe polymethyl methacrylate mixture of olefin(e) acid ethyl ester copolymer, ethylene-acrylic acid copolymer, at least two kinds of above-mentioned substances, withAnd combination.

11. polymer formulation product as claimed in claim 6, wherein said less important base resin is about 10wt%.

12. polymer formulation product as claimed in claim 11, wherein said less important acrylic resin is to be selected from lower group, described groupFormed by the following: crystalline polypropylene homopolymer, impact polypropylene copolymer, with and composition thereof.

13. polymer formulation product as claimed in claim 12, wherein said crystalline polypropylene homopolymer is cooling at 10 DEG C/minUnder speed, there is the crystalline phase that exceedes 51%.

14. polymer formulation product as claimed in claim 1, wherein said slip agent is to be up to about 5wt%.

15. polymer formulation product as claimed in claim 14, wherein said slip agent is approximately 1 to 3wt%.

16. polymer formulation product as claimed in claim 15, wherein said slip agent is about 2wt%.

17. polymer formulation product as claimed in claim 1, wherein said colouring agent is to be up to about 5wt%.

18. polymer formulation product as claimed in claim 17, wherein said colouring agent is approximately 0.5 to 4wt%.

19. polymer formulation product as claimed in claim 18, wherein said colouring agent is approximately 0.5 to 2wt%.

20. polymer formulation product as claimed in claim 19, wherein said colouring agent is about 0.5wt%.

21. polymer formulation product as claimed in claim 19, wherein said colouring agent is about 1wt%.

22. polymer formulation product as claimed in claim 1, wherein said nucleator is approximately 0.5 to 5wt%.

23. polymer formulation product as claimed in claim 22, wherein said nucleator is about 0.5wt%.

24. polymer formulation product as claimed in claim 1, wherein said CBA is approximately 0.1 to 5wt%.

25. polymer formulation product as claimed in claim 24, wherein said CBA is approximately 0.1 to 2wt%.

26. polymer formulation product as claimed in claim 25, wherein said CBA is approximately 0.1 to 1wt%.

27. polymer formulation product as claimed in claim 26, wherein said CBA is about 0.1wt%.

28. polymer formulation product as claimed in claim 1, wherein said base resin is acrylic resin.

29. polymer formulation product as claimed in claim 28, wherein said acrylic resin is high melt strength, propylene.

30. polymer formulation product as claimed in claim 1, wherein said base resin is have monomodal molecular weight distribution poly-Allyl resin.

31. polymer formulation product as claimed in claim 1, wherein said base resin has according to ISO16790 at least 36Melt strength.

32. polymer formulation product as claimed in claim 1, wherein said base resin has the fusion temperature of at least 163 DEG C.

33. polymer formulation product as claimed in claim 1, wherein said nucleator is selected from lower group, and described group by the followingComposition: the combination of chemical nucleation agent, physics nucleator and chemical nucleation agent and physics nucleator.

34. polymer formulation product as claimed in claim 33, wherein said chemical nucleation agent is citric acid or based on citric acidMaterial.

35. polymer formulation product as claimed in claim 33, wherein said physics nucleator is selected from lower group, described group by belowEvery composition: talcum, CaCO₃, in mica, kaolin, chitin, aluminosilicate, graphite, cellulose and above-mentioned thing extremelyThe mixture of few two kinds.

36. polymer formulation product as claimed in claim 1, further comprise physical blowing agent.

37. polymer formulation product as claimed in claim 36, wherein said physical blowing agent is selected from lower group, described group by belowEvery composition: carbon dioxide, nitrogen, helium, argon gas, air, steam, pentane, butane, with and composition thereof.

38. polymer formulation product as claimed in claim 36, wherein said physical blowing agent is selected from lower group, described group by belowEvery composition: hydrofluoroalkane, HF hydrocarbon, alkyl halide or alkyl halide cold-producing medium.

39. polymer formulation product as claimed in claim 38, wherein said hydrofluoroalkane is HFA 134a.

40. polymer formulation product as claimed in claim 38, wherein said HF hydrocarbon is 1,3,3,3-tetrafluoeopropene.

41. polymer formulation product as claimed in claim 40, further comprise and strengthen adding of described physical blowing agent solubilityWork auxiliary agent.

42. polymer formulation product as claimed in claim 41, wherein said physical blowing agent is that at least one does under pressureFor liquid is introduced into the gas in molten resin.

43. polymer formulation product as claimed in claim 33, wherein said CBA is selected from lower group, described group by belowEvery composition: Celogen Az; Azodiisobutyronitrile; Benzene sulfonyl hydrazide; 4,4-oxy-phenylsulfonamido urea; P-tosylSemicarbazides; Barium azodicarboxylate; N, N '-dimethyl-N, N '-dinitrosoterephthalamine; Trihydrazinotriazine; Methane; SecondAlkane; Propane; Normal butane; Iso-butane; Pentane; Isopentane; Neopentane; Fluoromethane; Perfluoromethane; Ethyl fluoride; 1,1-difluoro secondAlkane; 1,1,1-HFC-143a; HFA 134a; Pentafluoroethane; Hexafluoroethane; 2,2-difluoropropane; 1,1,1-trifluoroPropane; Perfluoropropane; Perfluorinated butane; Freon C318; Methyl chloride; METHYLENE CHLORIDE; Ethyl chloride; 1,1,1-trichloroethanes; 1,1-Two chloro-1-fluoroethanes; 1-chlorine-1,1-difluoroethane; 1,1-bis-is chloro-2,2,2-HFC-143a; 1-is chloro-1,2,2,2-tetrafluoro secondAlkane; Trichlorine list fluoromethane; Dicholorodifluoromethane; Trichorotrifluoroethane; Dichlorotetra-fluoroethane; Chlorine heptafluoro-propane; Dichloro hexafluoro thirdAlkane; Methyl alcohol; Ethanol; Normal propyl alcohol; Isopropyl alcohol; Sodium acid carbonate; Sodium carbonate; Carbonic hydroammonium; Ammonium carbonate; Ammonium nilrite; N, N '-diformazanBase-N, N '-dinitrosoterephthalamine; N, N '-dinitrosopentamethylene tetramine; Azodiisobutyronitrile; Azo hexamethyleneBase nitrile; Azo diaminobenzene; Benzene sulfonyl hydrazide; Toluene sulfonyl hydrazide; P, p '-oxo two (benzene sulfonyl hydrazide); Diphenyl sulfone-3,3 '-bis-Sulfonyl hydrazine; Azide calcium; 4,4 '-diphenyl disulfonyl base azide; And ptoluene-sulfonyl azide.

44. polymer formulation product as claimed in claim 1, wherein said slip agent is the acid amides, low point of fat or aliphatic acidSon amount acid amides or fluoroelastomer.

45. polymer formulation product as claimed in claim 44, wherein said fatty acid amide is monounsaturated C₁₈To C₂₂AcylAmine.

46. polymer formulation product as claimed in claim 44, wherein said fatty acid amide is erucyl amide or oleamide.

47. polymer formulation product as claimed in claim 1, wherein said colouring agent is titanium dioxide.

48. 1 kinds of polymeric materials, comprise

Polymer formulation product, base resin that described polymer formulation product comprise approximately 50 – 99.9wt%, are up to about 10wt%'sSlip agent, be up to about 10wt% colouring agent, be up to the one-tenth of the CBA of about 10wt% and approximately 0.5 – 10wt%Core agent, and

Wherein said polymeric material be abscess formula and non-aromatic.

49. polymeric materials as claimed in claim 48, wherein said base resin is homopolymer polypropylene.

50. polymeric materials as claimed in claim 49, wherein said polymeric material has approximately 1.0 to approximately 3.0 abscessAverage aspect ratio.

51. polymeric materials as claimed in claim 50, wherein said polymeric material has approximately 1.0 to approximately 2.0 abscessAverage aspect ratio.

52. polymeric materials as claimed in claim 51, wherein average abscess aspect ratio is approximately 2.0.

53. polymeric materials as claimed in claim 48, wherein said polymeric material has about 0.01g/cm³Extremely approximately0.19g/cm₃Density.

54. polymeric materials as claimed in claim 53, wherein said polymeric material has about 0.05g/cm³Extremely approximately0.19g/cm₃Density.

55. polymeric materials as claimed in claim 48, wherein said polymeric material has about 0.1g/cm³Extremely approximately0.185g/cm₃Density.

56. polymeric materials as claimed in claim 48, wherein according to ASTMD1922-93, described polymeric material is at machineIn device direction, there is the tear resistance at least about 282 fors.

57. polymeric materials as claimed in claim 48, wherein according to Elmendorf method of testing ASTMD1922-93, instituteState polymeric material requires to tear described material at least about 282 fors in machine direction.

58. polymeric materials as claimed in claim 48, wherein according to as at ASTMD1922-93 described in Ai ErmenduoHusband's method of testing, described polymeric material structure requires to tear described material at least about 212 fors in a lateral direction.

59. polymeric materials as claimed in claim 48, wherein according to Elmendorf method of testing ASTMD1922-93, instituteState polymeric material requires to tear described material in approximately 213 fors to the power within the scope of approximately 351 fors in machine direction.

60. polymeric materials as claimed in claim 48, wherein according to Elmendorf method of testing ASTMD1922-93, instituteStating polymeric material requires to tear described material in approximately 143 fors to the power within the scope of approximately 281 fors in a lateral direction.

61. polymeric materials as claimed in claim 48, described polymeric material has about 0.05136W/m-K at 21 DEG CAverage thermal conductivity.

62. polymeric materials as claimed in claim 48, described polymeric material has about 0.06389W/m-K at 93 DEG CAverage thermal conductivity.

63. polymeric materials as claimed in claim 48, further comprise the laminated film of printing, wherein said polymeric materialMaterial has the average thermal conductivity of about 0.05321W/m-K at 21 DEG C.

64. polymeric materials as claimed in claim 48, further comprise the laminated film of printing, wherein said polymeric materialMaterial has the average thermal conductivity of about 0.06516W/m-K at 93 DEG C.

65. 1 kinds of insulating vessels, described insulating vessel comprises

The polymeric material of being made by polymer formulation product, the basis tree that described polymer formulation product comprise approximately 50 – 99.9wt%Fat, be up to about 10wt% slip agent, be up to about 10wt% colouring agent, be up to about 10wt% CBA,And the nucleator of approximately 0.5 – 10wt%,

Wherein said insulating vessel has the mean wall thickness of about 1.4mm to about 1.8mm, and

Described polymeric material has about 0.16g/cm³To about 0.19g/cm³Averag density.

66. insulating properties containers as described in claim 65, wherein said insulating properties container is at the liquid filling with approximately 93.3 DEG CAnd after being placed in to described container upper 5 minute, lid there is the outside wall temperature of approximately 49 DEG C to approximately 63 DEG C.

67. insulating properties containers as described in claim 65, wherein said insulating properties container is at the liquid filling with approximately 93.3 DEG CAnd after lid is placed on described container, be less than 5 minutes and there is maximum outside wall temperature.

68. insulating properties containers as described in claim 67, wherein, at the liquid filling with approximately 93.3 DEG C and lid is placed in to instituteStated after insulating properties container upper 5 minute, described outside wall temperature is lower than described maximum outside wall temperature.

69. 1 kinds of methods for the preparation of insulating materials, described method comprises

A) mixed polymer preparation, base resin that described polymer formulation product comprise approximately 50 – 99.9wt%, is up to approximatelyThe slip agent of 10wt%, be up to about 10wt% colouring agent, be up to the CBA of about 10wt% and approximately 0.5 –The nucleator of 10wt%,

B) preparation of described mixing is heated to molten condition,

C) at least one physical blowing agent is added in preparation described melting, that mix, and

D) extrude described preparation as extrudate.

70. methods as described in claim 69, wherein said at least one blowing agent is selected from lower group, and described group by the followingComposition: carbon dioxide, nitrogen, helium, argon gas, air, steam, pentane, butane, hydrofluoroalkane, HF hydrocarbon, alkyl halide, halogenFor alkane cold-producing medium, with and composition thereof.

71. methods as described in claim 70, wherein step (d) is included under the mass flow rate of about 9.8lbs/hr and addsAdd described at least one blowing agent.

72. 1 kinds form the method for insulative polymer material, and described method comprises

A) blend

I) there is the high melt strength, propylene base resin of long chain branching,

Ii) the second polymer, described the second polymer comprises polypropylene copolymer, polypropylene homopolymer, polyethylene or its mixingThing, and

Iii) at least one Nucleating Agent, to form resin compound,

B) heat described resin compound,

C) at least one blowing agent is added in described resin compound, and

D) extruding described resin compound has in the structure of the abscess that wherein formed to form.

73. methods as described in claim 72, wherein a) blend further comprises iv) slip agent, colouring agent or slip agent andColouring agent both.

74. methods as described in claim 72, wherein said blowing agent is physical blowing agent.

75. methods as described in claim 74, wherein said physical blowing agent is carbon dioxide.

76. methods as described in claim 72, wherein said structure is thin slice.

77. methods as described in claim 76, further comprise and e) cut described thin slice and f) form cup.

78. 1 kinds of polymer formulation product, comprise

A) base resin of about 96wt% or 97wt%, the less important base resin that wherein said base resin comprises about 10wt%;

B) slip agent of about 2wt%;

C) colouring agent of about 0.5wt%;

D) CBA of about 0.1wt%; And

E) approximately 0.5% nucleator.